Systems and methods for additively manufacturing composite parts

ABSTRACT

A system ( 100 ) for additively manufacturing a composite part ( 102 ) is disclosed. The system ( 100 ) comprises a delivery guide ( 112 ), movable relative to a surface ( 114 ). The delivery guide ( 112 ) is configured to deposit at least a segment ( 120 ) of a continuous flexible line ( 106 ) along a print path ( 122 ). The print path ( 122 ) is stationary relative to the surface ( 114 ). The continuous flexible line ( 106 ) comprises a non-resin component ( 108 ) and a thermosetting-epoxy-resin component ( 110 ) that is partially cured. The system ( 100 ) also comprises a feed mechanism ( 104 ), configured to push the continuous flexible line ( 106 ) through the delivery guide ( 112 ). The system ( 100 ) further comprises a cooling system ( 234 ), configured to maintain the thermosetting-epoxy-resin component ( 110 ) of the continuous flexible line ( 106 ) below a threshold temperature prior to depositing the segment ( 120 ) of the continuous flexible ( 106 ) along the print path ( 122 ) via the delivery guide ( 112 ).

RELATED APPLICATION

This application claims priority to U.S. Provisional Patent ApplicationNo. 62/199,665, entitled “SYSTEMS AND METHODS FOR ADDITIVELYMANUFACTURING COMPOSITE PARTS,” which was filed on Jul. 31, 2015, andthe complete disclosure of which is hereby incorporated by reference.

BACKGROUND

Conventionally, manufacturing of typical composite parts relies onsequential layering of multiple plies of composite material, with eachply containing, e.g., unidirectional reinforcement fibers or randomlyoriented chopped fibers. Parts manufactured in this manner must havelaminar construction, which undesirably increases the weight of thefinished part, since not all of the reinforcement fibers are orientedalong the direction(s) of the force(s) to be applied to the parts.Additionally, limitations inherent to laminar techniques ofmanufacturing composites are not conducive to implementation of manytypes of advanced structural designs.

SUMMARY

Accordingly, apparatuses and methods, intended to address at least theabove-identified concerns, would find utility.

The following is a non-exhaustive list of examples, which may or may notbe claimed, of the subject matter according the present disclosure.

One example of the present disclosure relates to a system for additivelymanufacturing a composite part. The system comprises a delivery guide,movable relative to a surface. The delivery guide is configured todeposit at least a segment of a continuous flexible line along a printpath. The print path is stationary relative to the surface. Thecontinuous flexible line comprises a non-resin component and athermosetting-epoxy-resin component that is partially cured. The systemalso comprises a feed mechanism, configured to push the continuousflexible line through the delivery guide. The system further comprises acooling system, configured to maintain the thermosetting-epoxy-resincomponent of the continuous flexible line below a threshold temperatureprior to depositing the segment of the continuous flexible along theprint path via the delivery guide.

Another example of the present disclosure relates to a method ofadditively manufacturing a composite part. The method comprises pushinga continuous flexible line through a delivery guide. The continuousflexible line comprises a non-resin component and athermosetting-epoxy-resin component that is partially cured. The methodalso comprises depositing, via the delivery guide, a segment of thecontinuous flexible line along a print path. The method furthercomprises maintaining the thermosetting-epoxy-resin component of atleast the continuous flexible line being pushed through the deliveryguide below a threshold temperature prior to depositing the segment ofthe continuous flexible line along the print path.

Yet another example of the present disclosure relates to a method ofadditively manufacturing a composite part. The method comprisesdepositing, via a delivery guide, a segment of a continuous flexibleline along a print path. The continuous flexible line comprises anon-resin component and a thermosetting-epoxy-resin component that ispartially cured. The method also comprises maintaining thethermosetting-epoxy-resin component of at least the continuous flexibleline being advanced toward the print path via the delivery guide below athreshold temperature prior to depositing the segment of the continuousflexible line along the print path. The method further comprisesdelivering a predetermined or actively determined amount of curingenergy at least to a portion of the segment of the continuous flexibleline at a controlled rate while advancing the continuous flexible linetoward the print path and after the segment of the continuous flexibleline is deposited along the print path to at least partially cure atleast the portion of the segment of the continuous flexible line.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described examples of the present disclosure in generalterms, reference will now be made to the accompanying drawings, whichare not necessarily drawn to scale, and wherein like referencecharacters designate the same or similar parts throughout the severalviews, and wherein:

FIG. 1 is a schematic diagram of a system for additively manufacturing acomposite part, according to one or more examples of the presentdisclosure;

FIG. 2 is a schematic cross-sectional view of a continuous flexible linedeposited by the system of FIG. 1, according to one or more examples ofthe present disclosure;

FIG. 3 is schematic cross-sectional view of a continuous flexible linedeposited by the system of FIG. 1, according to one or more examples ofthe present disclosure;

FIG. 4 is a schematic illustration of a portion of the system of FIG. 1,in which two layers of continuous flexible line are being curedsimultaneously, according to one or more examples of the presentdisclosure;

FIG. 5 is a schematic illustration of a portion of the system of FIG. 1,in which a delivery guide comprises a curing-energy passage, accordingto one or more examples of the present disclosure;

FIG. 6 is a schematic illustration of a portion of the system of FIG. 1,in which a delivery guide comprises a curing-energy passage and curingenergy is delivered in the form of a ring, according to one or moreexamples of the present disclosure;

FIG. 7 is a schematic illustration of a portion of the system of FIG. 1,in which curing energy is delivered in the form of a ring, according toone or more examples of the present disclosure;

FIG. 8 is a schematic illustration of a feed assembly and a deliveryguide of the system of FIG. 1, according to one or more examples of thepresent disclosure;

FIG. 9 is a schematic diagram of a roller and a scraper of a feedmechanism of the system of FIG. 1, according to one or more examples ofthe present disclosure;

FIG. 10 is a schematic illustration of a compactor comprising acompaction roller of the system of FIG. 1, according to one or moreexamples of the present disclosure;

FIG. 11 is a schematic illustration of a portion of the system of FIG. 1with a compactor comprising a compaction roller, according to one ormore examples of the present disclosure;

FIG. 12 is a schematic illustration of a portion of the system of FIG. 1with a compactor comprising a compaction roller, according to one ormore examples of the present disclosure;

FIG. 13 is a schematic illustration of a portion of the system of FIG. 1with a compactor comprising a compaction wiper, according to one or moreexamples of the present disclosure;

FIG. 14 is a schematic illustration of a portion of the system of FIG. 1with a compactor comprising a skirt, according to one or more examplesof the present disclosure;

FIG. 15 is a schematic illustration of a cutter comprising aniris-diaphragm of the system of FIG. 1, according to one or moreexamples of the present disclosure;

FIG. 16 is a schematic illustration of a portion of the system of FIG. 1with a cutter comprising two blades movable relative to a deliveryguide, according to one or more examples of the present disclosure;

FIG. 17 is a schematic illustration of a portion of the system of FIG. 1with a cutter comprising at least one blade positioned within a deliveryguide, according to one or more examples of the present disclosure;

FIG. 18 is a schematic illustration of the system of FIG. 1 with acutter comprising a cutting laser, according to one or more examples ofthe present disclosure;

FIG. 19 is a schematic illustration of the system of FIG. 1 with asource of curing energy comprising one or more curing lasers, accordingto one or more examples of the present disclosure;

FIG. 20 is a view of the system of FIG. 1 comprising a frame and a driveassembly, according to one or more examples of the present disclosure;

FIG. 21 is a view of a portion of the system of FIG. 1 with a cutter, acompactor, a surface roughener, and a curing source comprising a curinglaser, according to one or more examples of the present disclosure;

FIG. 22 is a view of a portion of the system of FIG. 1 with a curingsource comprising a curing laser, according to one or more examples ofthe present disclosure;

FIG. 23 is a view of a portion of the system of FIG. 1 with a compactorand a curing source comprising a curing laser, according to one or moreexamples of the present disclosure;

FIG. 24 is a view of a portion of the system of FIG. 1 with a curingsource comprising a curing laser, according to one or more examples ofthe present disclosure;

FIG. 25 is a view of a portion of the system of FIG. 1 with a curingsource comprising two curing lasers, according to one or more examplesof the present disclosure;

FIG. 26 is a view of a portion of the system of FIG. 1 with a curingsource comprising four curing lasers, according to one or more examplesof the present disclosure;

FIG. 27 is a view of a portion of the system of FIG. 1 with a feedmechanism, according to one or more examples of the present disclosure;

FIG. 28 is another view of the portion of FIG. 27;

FIG. 29 is another view of the portion of FIG. 27;

FIG. 30 is a view of a portion of the system of FIG. 1 with a cuttercomprising two blades movable relative to a delivery guide, according toone or more examples of the present disclosure;

FIG. 31 is another view of the portion of FIG. 30;

FIGS. 32A, 328, and 32C collectively are a block diagram of a method foradditively manufacturing composite parts, according to one or moreexamples of the present disclosure;

FIGS. 33A, 338, and 33C collectively are a block diagram of a method foradditively manufacturing composite parts, according to one or moreexamples of the present disclosure;

FIG. 34 is a block diagram representing aircraft production and servicemethodologies;

FIG. 35 is a schematic illustration of an aircraft; and

FIG. 36 is a schematic illustration of the system of FIG. 1, in whichtwelve degrees of freedom are provided between a delivery guide and asurface, according to one or more examples of the present disclosure.

DETAILED DESCRIPTION

In FIG. 1, referred to above, solid lines, if any, connecting variouselements and/or components may represent mechanical, electrical, fluid,optical, electromagnetic and other couplings and/or combinationsthereof. As used herein, “coupled” means associated directly as well asindirectly. For example, a member A may be directly associated with amember B, or may be indirectly associated therewith, e.g., via anothermember C. It will be understood that not all relationships among thevarious disclosed elements are necessarily represented. Accordingly,couplings other than those depicted in the schematic diagram may alsoexist. Dashed lines, if any, connecting blocks designating the variouselements and/or components represent couplings similar in function andpurpose to those represented by solid lines; however, couplingsrepresented by the dashed lines may either be selectively provided ormay relate to alternative examples of the present disclosure. Likewise,elements and/or components, if any, represented with dashed lines,indicate alternative examples of the present disclosure. One or moreelements shown in solid and/or dashed lines may be omitted from aparticular example without departing from the scope of the presentdisclosure. Environmental elements, if any, are represented with dottedlines. Virtual imaginary elements may also be shown for clarity. Thoseskilled in the art will appreciate that some of the features illustratedin FIG. 1 may be combined in various ways without the need to includeother features described in FIG. 1, other drawing figures, and/or theaccompanying disclosure, even though such combination or combinationsare not explicitly illustrated herein. Similarly, additional featuresnot limited to the examples presented, may be combined with some or allof the features shown and described herein.

In FIGS. 32-34, referred to above, the blocks may represent operationsand/or portions thereof and lines connecting the various blocks do notimply any particular order or dependency of the operations or portionsthereof. Blocks represented by dashed lines indicate alternativeoperations and/or portions thereof. Dashed lines, if any, connecting thevarious blocks represent alternative dependencies of the operations orportions thereof. It will be understood that not all dependencies amongthe various disclosed operations are necessarily represented. FIGS.32-34 and the accompanying disclosure describing the operations of themethod(s) set forth herein should not be interpreted as necessarilydetermining a sequence in which the operations are to be performed.Rather, although one illustrative order is indicated, it is to beunderstood that the sequence of the operations may be modified whenappropriate. Accordingly, certain operations may be performed in adifferent order or simultaneously. Additionally, those skilled in theart will appreciate that not all operations described need be performed.

In the following description, numerous specific details are set forth toprovide a thorough understanding of the disclosed concepts, which may bepracticed without some or all of these particulars. In other instances,details of known devices and/or processes have been omitted to avoidunnecessarily obscuring the disclosure. While some concepts will bedescribed in conjunction with specific examples, it will be understoodthat these examples are not intended to be limiting.

Unless otherwise indicated, the terms “first,” “second,” etc. are usedherein merely as labels, and are not intended to impose ordinal,positional, or hierarchical requirements on the items to which theseterms refer. Moreover, reference to, e.g., a “second” item does notrequire or preclude the existence of, e.g., a “first” or lower-numbereditem, and/or, e.g., a “third” or higher-numbered item.

Reference herein to “one example” means that one or more feature,structure, or characteristic described in connection with the example isincluded in at least one implementation. The phrase “one example” invarious places in the specification may or may not be referring to thesame example.

As used herein, a system, apparatus, structure, article, element, orcomponent “configured to” perform a specified function is indeed capableof performing the specified function without any alteration, rather thanmerely having potential to perform the specified function after furthermodification. In other words, the system, apparatus, structure, article,element, or component is specifically selected, created, implemented,utilized, programmed, and/or designed for the purpose of performing thespecified function. As used herein, “configured to” denotes existingcharacteristics of a system, apparatus, structure, article, element, orcomponent which enable the system, apparatus, structure, article,element, or component to actually perform the specified function. Forpurposes of this disclosure, a system, apparatus, structure, article,element, or component described as being “configured to” perform aparticular function may additionally or alternatively be described asbeing “adapted to” and/or as being “operative to” perform that function.

Illustrative, non-exhaustive examples, which may or may not be claimed,of the subject matter according the present disclosure are providedbelow.

Referring, e.g., to FIG. 1, system 100 for additively manufacturingcomposite part 102 is disclosed. System 100 comprises delivery guide112, movable relative to surface 114. Delivery guide 112 is configuredto deposit at least segment 120 of continuous flexible line 106 alongprint path 122. Print path 122 is stationary relative to surface 114.Continuous flexible line 106 comprises non-resin component 108 andthermosetting-epoxy-resin component 110 that is partially cured. System100 also comprises feed mechanism 104, configured to push continuousflexible line 106 through delivery guide 112. System 100 furthercomprises cooling system 234, configured to maintainthermosetting-epoxy-resin component 110 of continuous flexible line 106below a threshold temperature prior to depositing segment 120 ofcontinuous flexible 106 along print path 122 via delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 1 ofthe present disclosure.

System 100 therefore may be used to manufacture composite parts 102 fromat least a composite material that includes non-resin component 108 andthermosetting-epoxy-resin component 110. Moreover, system 100 may beused to manufacture composite parts 102 with continuous flexible line106 being oriented in desired and/or predetermined orientationsthroughout composite part 102, such as to define desired properties ofcomposite part 102. System 100 includes cooling system 234 to maintainthermosetting-epoxy-resin component 110 in a partially cured state priorto continuation flexible line 106 being deposited relative to surface114 via delivery guide 112.

Some examples of system 100 additionally or alternatively may bedescribed as 3-D printers.

As mentioned, feed mechanism 104 is configured to push continuousflexible line 106 through delivery guide 112. In other words, deliveryguide 112, which deposits continuous flexible line 106 along print path122, is positioned downstream of feed mechanism 104 with respect to adirection of movement of continuous flexible line 106 when compositepart 102 is being manufactured by system 100.

As used herein, a “continuous flexible line” is an elongate structurehaving a length significantly longer than a dimension (e.g., diameter orwidth) that is transverse, or perpendicular, to its length. As anillustrative, non-exclusive example, continuous flexible line 106 mayhave a length that is at least 100, at least 1000, at least 10000, atleast 100000, or at least 1000000 times greater than its diameter orwidth.

As mentioned, continuous flexible line 106 comprises non-resin component108 and thermosetting-epoxy-resin component 110 that is partially cured.Because thermosetting-epoxy-resin component 110 is partially cured, andis not in liquid form, or at least not in a low viscosity form,continuous flexible line 106 may be manipulated by system 100, such thatthermosetting-epoxy-resin component 110 and non-resin component 108remain at least substantially together during manipulation by system 100and ultimately during deposition along print path 122 by delivery guide112.

As used herein, a “thermosetting-epoxy-resin component” is an epoxyresin material that is configured to be cured, or hardened, by selectiveapplication of heat and/or radiation, and/or by time above a thresholdcuring temperature. In the case of system 100, according to one or moreexamples thereof, because thermosetting-epoxy-resin component 110 ispartially cured, thermosetting-epoxy-resin component 110 is a resinmaterial that is configured to be further cured, or further hardened, byselective application of heat and/or by time above a threshold curingtemperature.

As mentioned, delivery guide 112 is movable relative to surface 114.This means that in some examples, system 100 may include delivery guide112 that is configured to be selectively moved relative to surface 114,which surface 114 may be a part of system 100 or a part of a structure,such as an airplane wing or a fuselage, etc. Additionally, in exampleswhere system 100 includes surface 114, surface 114 may be selectivelymoved relative to delivery guide 112. Also, in some examples, system 100may include delivery guide 112 and surface 114, and both may beselectively moved relative to each other.

Referring generally to FIG. 1, continuous flexible line 106 comprises aprepreg composite material. The preceding subject matter of thisparagraph characterizes example 2 of the present disclosure, whereinexample 2 also includes the subject matter according to example 1,above.

Because continuous flexible line 106 comprises a prepreg compositematerial, the component parts of continuous flexible line 106, namelynon-resin component 108 and thermosetting-epoxy-resin component 110, maybe received by feed mechanism 104, delivered to delivery guide 112, anddeposited along print path 122 as a continuous source material forcomposite part 102. Moreover, as composite part 102 is being formed, thenatural tackiness of the prepreg composite material may facilitateadhesion between layers being deposited by system 100.

As used herein, a “prepreg composite material” is a composite materialthat includes a structural material, typically a fiber or fibers, thatis impregnated with, or otherwise within, a partially cured matrix, orbinding material—in this example, non-resin component 108 is in a matrixof partially cured thermosetting-epoxy-resin component 110. The bindingmaterial is partially cured, or pre-cured, so as to permit handling ofthe composite material and selective assembly thereof. Prepreg compositematerial is in contrast with wet-layup and other applications ofcomposite materials where the binding material is applied in liquid formto the underlying structural material during a manufacturing process.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 2 and 3,non-resin component 108 of continuous flexible line 106 comprises one ormore of a fiber, a carbon fiber, a glass fiber, a synthetic organicfiber, an aramid fiber, a natural fiber, a wood fiber, a boron fiber, asilicon-carbide fiber, an optical fiber, a fiber bundle, a fiber tow, afiber weave, a wire, a metal wire, a conductive wire, or a wire bundle.The preceding subject matter of this paragraph characterizes example 3of the present disclosure, wherein example 3 also includes the subjectmatter according to any one of examples 1 or 2, above.

Inclusion of a fiber or fibers in continuous flexible line 106 permitsfor selecting desired properties of composite part 102. Moreover,selection of specific materials of fibers and/or selection of specificconfigurations of fibers (e.g., a bundle, a tow, and/or a weave) maypermit for precise selection of desired properties of composite part102. Example properties of composite parts 102 include strength,stiffness, flexibility, ductility, hardness, electrical conductivity,thermal conductivity, etc. Non-resin component 108 is not limited to theidentified examples, and other types of non-resin component 108 may beused.

FIG. 2 schematically represents continuous flexible line 106 with asingle fiber as non-resin component 108 within a matrix ofthermosetting-epoxy-resin component 110. FIG. 3 schematically representscontinuous flexible 106 with more than one fiber as non-resin component108 within a matrix of thermosetting-epoxy-resin component 110.

Referring generally to FIG. 1, system 100 further comprises origin 126of continuous flexible line 106. The preceding subject matter of thisparagraph characterizes example 4 of the present disclosure, whereinexample 4 also includes the subject matter according to any one ofexamples 1-3, above.

System 100, with origin 126, includes the material itself that definescontinuous flexible line 106. When provided, origin 126 may provide oneor more continuous flexible lines 106, such as including a firstcontinuous flexible line 106 with first desired properties and a secondcontinuous flexible line 106 with second desired properties that aredifferent from the first desired properties. For example, when more thanone continuous flexible line 106 is provided, different non-resincomponents 108 and/or different thermosetting-epoxy-resin components 110may be selected for desired properties of composite part 102.

Referring generally to FIG. 1, origin 126 of continuous flexible line106 comprises spool 128 of continuous flexible line 106. The precedingsubject matter of this paragraph characterizes example 5 of the presentdisclosure, wherein example 5 also includes the subject matter accordingto example 4, above.

Origin 126 in the form of spool 128 may provide a significant length ofcontinuous flexible line 106 in a compact volume that is readilyreplenished or replaced during a manufacturing operation.

Accordingly, feed mechanism 104 may be configured to draw, or pull,continuous flexible line 106 from spool 128.

Additionally or alternatively, origin 126 of continuous flexible line106 may comprise a plurality of individual lengths of continuousflexible line 106.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 20,cooling system 234 comprises insulated store 244, and origin 126 ispositioned within insulated store 244. The preceding subject matter ofthis paragraph characterizes example 6 of the present disclosure,wherein example 6 also includes the subject matter according to any oneof examples 4 or 5, above.

Inclusion of insulated store 244 with origin 126 facilitates maintainingthermosetting-epoxy-resin component 110 of continuous flexible line 106below a threshold temperature prior to being fed by feed mechanism 104,and thus facilitates prevention of further curing ofthermosetting-epoxy-resin component 110.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 20,cooling system 234 is configured to maintain origin 126 below thethreshold temperature. The preceding subject matter of this paragraphcharacterizes example 7 of the present disclosure, wherein example 7also includes the subject matter according to example 6, above.

Accordingly, thermosetting-epoxy-resin component 110 is prevented fromfurther curing while part of origin 126.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 20,cooling system 234 comprises pump 238 and coolant line 240,communicatively coupled with pump 238 and thermally coupled withinsulated store 244. Pump 238 is configured to circulate coolant 246through coolant line 240 to cool insulated store 244. The precedingsubject matter of this paragraph characterizes example 8 of the presentdisclosure, wherein example 8 also includes the subject matter accordingto any one of examples 6-7, above.

Pump 238 may be used to circulate coolant 246 through coolant line 240,which due to being thermally coupled with insulated store 244, drawsheat away from insulated store 244 and further facilitates maintainingthermosetting-epoxy-resin component 100 below a threshold temperatureand thus facilitates preventing further curing thereof while housed ininsulated store 244.

Other mechanisms for maintaining insulated store 244 and origin 126below a threshold temperature, including mechanisms that utilize arefrigeration cycle, also are within the scope of the presentdisclosure.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 20,cooling system 234 further comprises insulated sleeve 242. Feedmechanism 104 is configured to pull continuous flexible line 106 throughinsulated sleeve 242. Insulated sleeve 242 is thermally coupled withcoolant line 240, configured to internally cool insulated sleeve 242.The preceding subject matter of this paragraph characterizes example 9of the present disclosure, wherein example 9 also includes the subjectmatter according to example 8, above.

Insulated sleeve 242 may be provided to further prevent further curingof thermosetting-epoxy-resin component 110 as it is pulled from origin126 to feed mechanism 104. Moreover, in this example, insulated sleeve242 is thermally coupled with coolant line 240, and thus coolant 246further facilitates maintaining thermosetting-epoxy-resin component 100below a threshold temperature as it is being pulled through insulatedsleeve 242.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 20,cooling system 234 comprises insulated sleeve 242. Feed mechanism 104 isconfigured to pull continuous flexible line 106 through insulated sleeve242. The preceding subject matter of this paragraph characterizesexample 10 of the present disclosure, wherein example 10 also includesthe subject matter according to any one of examples 1-8, above.

Insulated sleeve 242 may be provided to further prevent further curingof thermosetting-epoxy-resin component 110 as it is pulled from origin126 to feed mechanism 104.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 4-7, 12,19, and 21-26, system 100 further comprises source 116 of curing energy118. Source 116 is configured to deliver curing energy 118 at least toportion 124 of segment 120 of continuous flexible line 106 after segment120 of continuous flexible line 106 exits delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 11 ofthe present disclosure, wherein example 11 also includes the subjectmatter according to any one of examples 1-10, above.

Inclusion of source 116 provides a mechanism forthermosetting-epoxy-resin component 110 to be further cured, andoptionally fully cured, as continuous flexible line 106 is beingdeposited relative to surface 114 via delivery guide 112. That is,composite part 102 if at least partially cured, and in some examplesfully cured, as it is being manufactured, or in situ.

As illustrative, non-exclusive examples, thermosetting-epoxy-resincomponent 110 may be configured to be cured, or hardened, when curingenergy 118 in the form of heat delivered via radiation, convention,and/or conduction.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 4-7, 12,19, and 21-26, source 116 of curing energy 118 is configured to delivercuring energy 118 at least to portion 124 of segment 120 of continuousflexible line 106 as feed mechanism 104 pushes continuous flexible line106 through delivery guide 112 toward print path 122 and after segment120 of continuous flexible line 106 is deposited along print path 122.The preceding subject matter of this paragraph characterizes example 12of the present disclosure, wherein example 12 also includes the subjectmatter according to example 11, above.

By delivering curing energy 118 to portion 124 of segment 120 ofcontinuous flexible line 106 after segment 120 is deposited by deliveryguide 112, thermosetting-epoxy-resin component 110 within portion 124 isat least further cured, so that portion 124 is effectively fixed in adesired place relative to the remainder of segment 120 having beenalready deposited by delivery guide 112. In other words, source 116provides for in situ curing of composite part 102 as it is beingmanufactured by system 100.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 4-7, 12,19, and 21-26, source 116 of curing energy 118 is configured to delivera predetermined or actively determined amount of curing energy 118 at acontrolled rate at least to portion 124 of segment 120 of continuousflexible line 106. The preceding subject matter of this paragraphcharacterizes example 13 of the present disclosure, wherein example 13also includes the subject matter according to any one of examples 11 or12, above.

As a result of delivering a predetermined or actively determined amountof curing energy 118 at a controlled rate, a desired level, or degree,of cure may be established with respect to portion 124 of segment 120 atany given time during manufacture of composite part 102. For example, itmay be desirable to cure one portion 124 greater than or less thananother portion 124 during manufacture of composite part 102. Apredetermined amount of curing energy 118 may be based, e.g., on thethermosetting epoxy resin used for thermosetting-epoxy-resin component110. An actively determined amount of curing energy 118 may be based,e.g., on real-time data sensed from continuous flexible line 106 as itis being deposited, including (but not limited to) hardness, color,temperature, glow, etc.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 4-7, 12,19, and 21-26, source 116 of curing energy 118 comprises one or morecuring lasers 134. The preceding subject matter of this paragraphcharacterizes example 14 of the present disclosure, wherein example 14also includes the subject matter according to any one of examples 11-13,above.

Inclusion of one or more curing lasers 134 facilitates a concentratedand directed stream of curing energy 118, such that curing energy 118may be selectively and precisely directed at portion 124 of segment 120during manufacture of composite part 102.

Referring generally to FIG. 1, source 116 of curing energy 118 comprisesone or more ultraviolet-light sources, infrared-light sources, or x-raysources. The preceding subject matter of this paragraph characterizesexample 15 of the present disclosure, wherein example 15 also includesthe subject matter according to any one of examples 11-14, above.

Inclusion of one or more ultraviolet-light sources, infrared-lightsources, or x-ray sources permits for use of thermosetting epoxy resinsfor thermosetting-epoxy-resin component 110 that are configured to befurther cured via radiation from ultraviolet light, infrared light, orx-rays.

Referring generally to FIG. 1, source 116 of curing energy 118 comprisesone or more visible light sources. The preceding subject matter of thisparagraph characterizes example 16 of the present disclosure, whereinexample 16 also includes the subject matter according to any one ofexamples 11-15, above.

Inclusion of one or more visible light sources permits for use ofthermosetting epoxy resins for thermosetting-epoxy-resin component 110that are configured to be further cured via radiation from visiblelight.

Referring generally to FIG. 1, source 116 of curing energy 118 comprisesheat source 136. The preceding subject matter of this paragraphcharacterizes example 17 of the present disclosure, wherein example 17also includes the subject matter according to any one of examples 11-16,above.

Inclusion of heat source 136 permits for use of thermosetting epoxyresins for thermosetting-epoxy-resin component 110 that are configuredto be further cured via heat delivered by heat source 136.

Referring generally to FIG. 1, heat source 136 comprises convective heatsource 250. The preceding subject matter of this paragraph characterizesexample 18 of the present disclosure, wherein example 18 also includesthe subject matter according to example 17, above.

Inclusion of convective heat source 250 permits for use of thermosettingepoxy resins for thermosetting-epoxy-resin component 110 that areconfigured to be further cured via heat delivered by convection.

Referring generally to FIG. 1, curing energy 118 comprises a hot gasstream. The preceding subject matter of this paragraph characterizesexample 19 of the present disclosure, wherein example 19 also includesthe subject matter according to example 18, above.

A hot gas stream may be an effective way to further curethermosetting-epoxy-resin component 110, depending on the specificconfiguration of thermosetting-epoxy-resin component 110. Moreover,production of a hot gas stream may be less expensive to implement than,for example, curing laser 134 as part of system 100.

Referring generally to FIG. 1, heat source 136 comprises radiative heatsource 252. The preceding subject matter of this paragraph characterizesexample 20 of the present disclosure, wherein example 20 also includesthe subject matter according to any one of examples 17-19, above.

Inclusion of radiative heat source 252 permits for use of thermosettingepoxy resins for thermosetting-epoxy-resin component 110 that areconfigured to be further cured via heat delivered by radiation.

Referring generally to FIG. 1, system 100 further comprises chamber 258.Delivery guide 112 and feed mechanism 104 are positioned within chamber258. Delivery guide 112 is configured to deposit segment 120 ofcontinuous flexible line 106 along print path 122 within chamber 258.Heat source 136 is configured to heat chamber 258. The preceding subjectmatter of this paragraph characterizes example 21 of the presentdisclosure, wherein example 21 also includes the subject matteraccording to any one of examples 17-20, above.

Providing chamber 258, within which continuous flexible line 106 isdeposited via delivery guide 112, and heating chamber 258 to furthercure thermosetting-epoxy-resin component 110 may provide an efficientway to cure thermosetting-epoxy-resin component 110 via heat withoutexpensive and complicated mechanisms that require concentrated anddirected heat at segment 120.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 10-14,21, and 23, heat source 136 comprises conductive heat source 254. Thepreceding subject matter of this paragraph characterizes example 22 ofthe present disclosure, wherein example 22 also includes the subjectmatter according to any one of examples 17-21, above.

Inclusion of conductive heat source 254 permits for use of thermosettingepoxy resins for thermosetting-epoxy-resin component 110 that areconfigured to be further cured via heat delivered by conduction, such asby conductive heat source 254 being placed in direct contact withportion 124 of segment 120 of continuous flexible line 106 after segment120 of continuous flexible line 106 exits delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 10-14,21, and 23, conductive heat source 254 comprises resistive heater 256.The preceding subject matter of this paragraph characterizes example 23of the present disclosure, wherein example 23 also includes the subjectmatter according to example 22, above.

Inclusion of resistive heater 256 may be an efficient and inexpensiveoption for generating heat for further curing thermosetting-epoxy-resincomponent 110 during manufacture of composite part by system 100.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 10-14,21, and 23, system 100 further comprises compactor 138, operativelycoupled to delivery guide 112. Compactor 138 is configured to impart acompaction force at least to section 180 of segment 120 of continuousflexible line 106 after segment 120 of continuous flexible line 106exits delivery guide 112. Compactor 138 comprises conductive heat source254. The preceding subject matter of this paragraph characterizesexample 24 of the present disclosure, wherein example 24 also includesthe subject matter according to any one of examples 22 or 23, above.

Compactor 138 compacts adjacent layers of continuous flexible line 106that have been deposited by delivery guide 112 along print path 122.Moreover, compactor 138 is in direct contact with segment 120 to impartthe compaction force thereto, and therefore may deliver heat viaconduction directly to segment 120.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 10-12,21, and 23, compactor 138 comprises compaction roller 182, havingcompaction-roller surface 184 that is configured to roll over at leastsection 180 of segment 120 of continuous flexible line 106 after segment120 of continuous flexible line 106 exits delivery guide 112.Compaction-roller surface 184 is heated by conductive heat source 254.The preceding subject matter of this paragraph characterizes example 25of the present disclosure, wherein example 25 also includes the subjectmatter according to example 24, above.

Compaction roller 182, compared to alternative examples of compactor138, may reduce the axial movement of thermosetting-epoxy-resincomponent 110 along segment 120 during compaction. Additionally,compared to alternative examples of compactor 138, compaction roller 182may provide a more desirable normal, or perpendicular, component of thecompaction force.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 10,compaction-roller surface 184 is textured. The preceding subject matterof this paragraph characterizes example 26 of the present disclosure,wherein example 26 also includes the subject matter according to example25, above.

When compaction-roller surface 184 is textured, compaction-rollersurface 184 imparts a texture to segment 120 or abrades segment 120,providing it with an increased surface area for better adhesion of asubsequent layer of continuous flexible line 106 deposited against it.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 11,compaction-roller surface 184 is shaped to impart a predeterminedcross-sectional shape at least to section 180 of segment 120 ofcontinuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. The preceding subject matter of thisparagraph characterizes example 27 of the present disclosure, whereinexample 27 also includes the subject matter according to any one ofexamples 25 or 26, above.

It may be desirable, in some applications, to impart a predeterminedcross-sectional shape to continuous flexible line 106 as it is beingdeposited by delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 13,compactor 138 comprises compaction wiper 185, having wiper drag surface186 that is configured to drag against at least section 180 of segment120 of continuous flexible line 106 after segment 120 of continuousflexible line 106 exits delivery guide 112. Wiper drag surface 186 isheated by conductive heat source 254. The preceding subject matter ofthis paragraph characterizes example 28 of the present disclosure,wherein example 28 also includes the subject matter according to example24, above.

Compaction wiper 185, compared to alternative examples of compactor 138,may increase the axial movement of thermosetting-epoxy-resin component110 along segment 120 during compaction.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 13, wiperdrag surface 186 is textured. The preceding subject matter of thisparagraph characterizes example 29 of the present disclosure, whereinexample 29 also includes the subject matter according to example 28,above.

When drag surface 186 is textured, drag surface 186 imparts a texture tosegment 120 or abrades segment 120, providing it with an increasedsurface area for better adhesion of a subsequent layer of continuousflexible line 106 deposited against it.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 13, wiperdrag surface 186 is shaped to impart a predetermined cross-sectionalshape to segment 120 of continuous flexible line 106 after segment 120of continuous flexible line 106 exits delivery guide 112. The precedingsubject matter of this paragraph characterizes example 30 of the presentdisclosure, wherein example 30 also includes the subject matteraccording to any one of examples 28 or 29, above.

As mentioned, it may be desirable, in some applications, to impart apredetermined cross-sectional shape to continuous flexible line 106 asit is being deposited by delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 12, 21,and 23, compactor 138 is biased toward section 180 of segment 120 ofcontinuous flexible line 106. The preceding subject matter of thisparagraph characterizes example 31 of the present disclosure, whereinexample 31 also includes the subject matter according to any one ofexamples 24-30, above.

By being biased toward section 180, compactor 138 imparts a desiredcompaction force against section 180.

Compactor 138 may be biased toward section 180, such as by spring 181 orother biasing member.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 12, 21,and 23, compactor 138 is rotatable relative to delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 32 ofthe present disclosure, wherein example 32 also includes the subjectmatter according to any one of examples 24-31, above.

By being rotatable relative to delivery guide 112, compactor 138 may beselectively positioned to impart its compaction force against section180 of segment 120 as delivery guide 112 moves, including as it changesdirections, relative to surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 12, 21,and 23, compactor 138 is configured to trail delivery guide 112 whendelivery guide 112 moves relative to surface 114. The preceding subjectmatter of this paragraph characterizes example 33 of the presentdisclosure, wherein example 33 also includes the subject matteraccording to any one of examples 24-32, above.

By trailing delivery guide 112, compactor 138 is selectively positionedto impart its compaction force against section 180 of segment 120directly following section 180 exiting delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 21 and23, system 100 further comprises pivoting arm 152, coupled relative todelivery guide 112 such that pivoting arm 152 trails delivery guide 112as delivery guide 112 moves relative to surface 114. Compactor 138 iscoupled to pivoting arm 152. The preceding subject matter of thisparagraph characterizes example 34 of the present disclosure, whereinexample 34 also includes the subject matter according to any one ofexamples 24-33, above.

Pivoting arm 152 provides for selective pivoting of compactor 138relative to delivery guide 112. Accordingly, compactor 138 may beselectively positioned to impart its compaction force against section180 of segment 120 as delivery guide 112 moves, including as it changesdirections, relative to surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 21 and23, system 100 further comprises pivoting-arm actuator 188, operativelycoupled to pivoting arm 152 and configured to actively control arotational position of pivoting arm 152 relative to delivery guide 112as delivery guide 112 moves relative to surface 114. The precedingsubject matter of this paragraph characterizes example 35 of the presentdisclosure, wherein example 35 also includes the subject matteraccording to example 34, above.

Pivoting-arm actuator 188 provides for selective pivoting of pivotingarm 152 and thus of compactor 138 relative to delivery guide 112.Accordingly, compactor 138 may be selectively positioned to impart itscompaction force against section 180 of segment 120 as delivery guide112 moves, including as it changes directions, relative to surface 114and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 21 and23, pivoting-arm actuator 188 is configured to actively coordinate therotational position of pivoting arm 152 with movement of delivery guide112 relative to surface 114. The preceding subject matter of thisparagraph characterizes example 36 of the present disclosure, whereinexample 36 also includes the subject matter according to example 35,above.

Accordingly, compactor 138 may be selectively and actively positioned toimpart its compaction force against section 180 of segment 120 asdelivery guide 112 moves, including as it changes directions, relativeto surface 114 and/or vice versa.

Referring to FIG. 14, compactor 138 comprises skirt 190, coupled todelivery guide 112. Skirt 190 comprises skirt drag surface 192 that ispositioned to drag against at least section 180 of segment 120 ofcontinuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. Skirt drag surface 192 is heated byconductive heat source 254. The preceding subject matter of thisparagraph characterizes example 37 of the present disclosure, whereinexample 37 also includes the subject matter according to example 24,above.

Skirt 190 extends from delivery guide 112 and circumferentially aroundoutlet 206. Accordingly, regardless of a direction of movement ofdelivery guide 112 relative to surface 114, and/or vice versa, skirt 90is positioned to compact section 180 of segment 120 of continuousflexible line 106 as it is being deposited.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises surface roughener 144, operatively coupled todelivery guide 112. Surface roughener 144 is configured to abrade atleast section 194 of segment 120 of continuous flexible line 106 aftersegment 120 of continuous flexible line 106 exits delivery guide 112.Surface roughener 144 comprises conductive heat source 254. Thepreceding subject matter of this paragraph characterizes example 38 ofthe present disclosure, wherein example 38 also includes the subjectmatter according to any one of examples 22-37, above.

Surface roughener 144 abrades section 194, providing it with anincreased surface area for better adhesion of a subsequent layerdeposited against it. Moreover, surface roughener 144 is in directcontact with segment 120 to abrade section 194, and therefore maydeliver heat via conduction directly to segment 120.

Referring generally to FIG. 1, surface roughener 144 comprisesroughening roller 196, having roughening roller surface 198 that isconfigured to rotationally abrade at least section 194 of segment 120 ofcontinuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. Roughening roller surface 198 isheated by conductive heat source 254. The preceding subject matter ofthis paragraph characterizes example 39 of the present disclosure,wherein example 39 also includes the subject matter according to example38, above.

Roughening roller 196, compared to alternative examples of surfaceroughener 144, may reduce the axial movement ofthermosetting-epoxy-resin component 110 along segment 120 duringabrasion thereof. Moreover, roughing roller surface 198, by being heatedby conductive heat source 254 and rolling against segment 120 mayprovide for efficient heat transfer, and thus curing, of section 194.

Referring generally to FIG. 1, roughening roller surface 198 is shapedto impart a predetermined cross-sectional shape to segment 120 ofcontinuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. The preceding subject matter of thisparagraph characterizes example 40 of the present disclosure, whereinexample 40 also includes the subject matter according to example 39,above.

It may be desirable, in some applications, to impart a predeterminedcross-sectional shape to continuous flexible line 106 as it is beingdeposited by delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21,surface roughener 144 comprises roughening drag surface 200 that isconfigured to translationally abrade at least section 194 of segment 120of continuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. Roughening drag surface 200 is heatedby conductive heat source 254. The preceding subject matter of thisparagraph characterizes example 41 of the present disclosure, whereinexample 41 also includes the subject matter according to example 38,above.

Roughening drag surface 200, compared to alternative examples of surfaceroughener 144, may increase the axial movement ofthermosetting-epoxy-resin component 110 along segment 120 duringabrasion thereof. Moreover, drag surface 200, by being heated byconductive heat source 254 and dragging against segment 120 may providefor efficient heat transfer, and thus curing, of section 194.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21,surface roughener 144 is biased toward section 194 of segment 120 ofcontinuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. The preceding subject matter of thisparagraph characterizes example 42 of the present disclosure, whereinexample 42 also includes the subject matter according to any one ofexamples 38-41, above.

By being biased toward section 194, surface roughener 144 imparts adesired abrasion force against section 194.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21,surface roughener 144 is rotatable relative to delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 43 ofthe present disclosure, wherein example 43 also includes the subjectmatter according to any one of examples 38-42, above.

By being rotatable relative to delivery guide 112, surface roughener 144may be selectively positioned to abrade section 194 as delivery guide112 moves, including as it changes directions, relative to surface 114and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21,surface roughener 144 is configured to trail delivery guide 112 whendelivery guide 112 moves relative to surface 114. The preceding subjectmatter of this paragraph characterizes example 44 of the presentdisclosure, wherein example 44 also includes the subject matteraccording to any one of examples 38-43, above.

By trailing delivery guide 112, surface roughener 144 is selectivelypositioned to abrade section 194 directly following segment 120 exitingdelivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises pivoting arm 152, configured such that pivotingarm 152 trails delivery guide 112 as delivery guide 112 moves relativeto surface 114. Surface roughener 144 is coupled to pivoting arm 152.The preceding subject matter of this paragraph characterizes example 45of the present disclosure, wherein example 45 also includes the subjectmatter according to any one of examples 38-44, above.

Pivoting arm 152 provides for selective pivoting of surface roughener144 relative to delivery guide 112. Accordingly, surface roughener 144may be selectively positioned to abrade section 194 as delivery guide112 moves, including as it changes directions, relative to surface 114and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises pivoting-arm actuator 188, operatively coupled topivoting arm 152 and configured to actively control a rotationalposition of pivoting arm 152 relative to delivery guide 112 as deliveryguide 112 moves relative to surface 114. The preceding subject matter ofthis paragraph characterizes example 46 of the present disclosure,wherein example 46 also includes the subject matter according to example45, above.

Pivoting-arm actuator 188 provides for selective pivoting of pivotingarm 152 and thus of surface roughener 144 relative to delivery guide112. Accordingly, surface roughener 144 may be selectively positioned toabrade section 194 as delivery guide 112 moves, including as it changesdirections, relative to surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21,pivoting-arm actuator 188 is configured to actively coordinate therotational position of pivoting arm 152 with movement of delivery guide112 relative to surface 114. The preceding subject matter of thisparagraph characterizes example 47 of the present disclosure, whereinexample 47 also includes the subject matter according to example 46,above.

Accordingly, surface roughener 144 may be selectively and activelypositioned to abrade section 194 as delivery guide 112 moves, includingas it changes directions, relative to surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises compactor 138. Surface roughener 144 is positionedto abrade at least section 194 of segment 120 of continuous flexibleline 106 following compaction of at least section 194 by compactor 138.The preceding subject matter of this paragraph characterizes example 48of the present disclosure, wherein example 48 also includes the subjectmatter according to any one of examples 38-47, above.

System 100 according to example 48 includes both compactor 138 andsurface roughener 144. By having surface roughener 144 positioned toabrade section 194 following compaction by compactor 138, the abrasionof section 194 is not hindered, or dulled, by a subsequent compactionthereof. Accordingly, abrasion of section 194 has an increased surfacearea for better adhesion of a subsequent layer deposited against it.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises debris inlet 202, configured to collect debrisresulting from abrading at least section 194 of segment 120 ofcontinuous flexible line 106 with surface roughener 144. The precedingsubject matter of this paragraph characterizes example 49 of the presentdisclosure, wherein example 49 also includes the subject matteraccording to any one of examples 38-48, above.

Collection by debris inlet 202 of debris that results from abrasion ofsection 194 by surface roughener 144, avoids unwanted, loose particlesof thermosetting-epoxy-resin component 110 becoming trapped betweenadjacent deposited layers of continuous flexible line 106 that mayotherwise result in unwanted properties of composite part 102.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises vacuum source 203, selectively communicativelycoupled with debris inlet 202. The preceding subject matter of thisparagraph characterizes example 50 of the present disclosure, whereinexample 50 also includes the subject matter according to example 49,above.

Vacuum source 202 draws air and debris from adjacent section 194 throughdebris inlet 202.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises pivoting arm 152, coupled relative to deliveryguide 112 such that pivoting arm 152 trails delivery guide 112 asdelivery guide 112 moves relative to surface 114. Debris inlet 202 isoperatively coupled to pivoting arm 152. The preceding subject matter ofthis paragraph characterizes example 51 of the present disclosure,wherein example 51 also includes the subject matter according to any oneof examples 49 or 50, above.

By being coupled to pivoting arm 152, debris inlet 202 is selectivelypositioned to collect debris directly from adjacent section 194 asdelivery guide 112 moves relative to surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises pivoting-arm actuator 188 operatively coupled topivoting arm 152 and configured to actively control a rotationalposition of pivoting arm 152 relative to delivery guide 112 as deliveryguide 112 moves relative to surface 114. The preceding subject matter ofthis paragraph characterizes example 52 of the present disclosure,wherein example 52 also includes the subject matter according to example51, above.

Pivoting-arm actuator 188, by actively controlling a rotational positionof pivoting arm 152 relative to delivery guide 112, ensures that debrisinlet 202 trails delivery guide 112 so that debris inlet 202 isselectively positioned to collect debris directly adjacent to section194 as delivery guide 112 moves relative to surface 114 and/or viceversa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21,pivoting-arm actuator 188 is configured to actively coordinate therotational position of pivoting arm 152 with movement of delivery guide112 relative to surface 114. The preceding subject matter of thisparagraph characterizes example 53 of the present disclosure, whereinexample 53 also includes the subject matter according to example 52,above.

Pivoting-arm actuator 188, by actively coordinating a rotationalposition of pivoting arm 152 relative to delivery guide 112, ensuresthat debris inlet 202 trails delivery guide 112 so that debris inlet 202is selectively positioned to collect debris directly adjacent to section194 as delivery guide 112 moves relative to surface 114 and/or viceversa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises pressurized-gas outlet 204, configured to dispersedebris, resulting from roughening of segment 120 of continuous flexibleline 106 by surface roughener 144, with a pressurized gas. The precedingsubject matter of this paragraph characterizes example 54 of the presentdisclosure, wherein example 54 also includes the subject matteraccording to any one of examples 38-53, above.

Dispersal by pressurized-gas outlet 204 of debris that results fromabrasion of section 194 by surface roughener 144, avoids unwanted, looseparticles of thermosetting-epoxy-resin component 110 becoming trappedbetween adjacent deposited layers of continuous flexible line 106 thatmay otherwise result in unwanted properties of composite part 102.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises pressurized-gas source 205, selectivelycommunicatively coupled with pressurized-gas outlet 204. The precedingsubject matter of this paragraph characterizes example 55 of the presentdisclosure, wherein example 55 also includes the subject matteraccording to example 54, above.

Pressurized-gas source 205 provides a source of the pressurized gas tobe delivered to section 194 via pressurized-gas outlet 204.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises pivoting arm 152, configured such that pivotingarm 152 trails delivery guide 112 as delivery guide 112 moves relativeto surface 114. Pressurized-gas outlet 204 is operatively coupled topivoting arm 152. The preceding subject matter of this paragraphcharacterizes example 56 of the present disclosure, wherein example 56also includes the subject matter according to any one of examples 54 or55, above.

By being coupled to pivoting arm 152, pressurized-gas outlet 204 isselectively positioned to collect debris directly from adjacent section194 as delivery guide 112 moves relative to surface 114 and/or viceversa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises pivoting-arm actuator 188, operatively coupled topivoting arm 152 and configured to actively control a rotationalposition of pivoting arm 152 relative to delivery guide 112 as deliveryguide 112 moves relative to surface 114. The preceding subject matter ofthis paragraph characterizes example 57 of the present disclosure,wherein example 57 also includes the subject matter according to example56, above.

Pivoting-arm actuator 188, by actively controlling a rotational positionof pivoting arm 152 relative to delivery guide 112, ensures thatpressurized-gas outlet 204 trails delivery guide 112 so thatpressurized-gas outlet 204 is selectively positioned to disperse debrisdirectly adjacent to section 194 as delivery guide 112 moves relative tosurface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21,pivoting-arm actuator 188 is configured to actively coordinate therotational position of pivoting arm 152 with movement delivery guide 112relative to surface 114. The preceding subject matter of this paragraphcharacterizes example 58 of the present disclosure, wherein example 58also includes the subject matter according to example 57, above.

Pivoting-arm actuator 188, by actively coordinating a rotationalposition of pivoting arm 152 relative to delivery guide 112, ensuresthat pressurized-gas outlet 204 trails delivery guide 112 so thatpressurized-gas outlet 204 is selectively positioned to disperse debrisdirectly adjacent to section 194 as delivery guide 112 moves relative tosurface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 21-23,system 100 further comprises pivoting arm 152, coupled relative todelivery guide 112 such that pivoting arm 152 trails delivery guide 112as delivery guide 112 moves relative to surface 114. Source 116 ofcuring energy 118 is coupled to pivoting arm 152. The preceding subjectmatter of this paragraph characterizes example 59 of the presentdisclosure, wherein example 59 also includes the subject matteraccording to any one of examples 11-23, above.

Pivoting arm 152 provides for selective pivoting of source 116 relativeto delivery guide 112. Accordingly, source 116 may be selectivelypositioned to deliver curing energy 118 to portion 124 of segment 120 asdelivery guide 112 moves, including as it changes directions, relativeto surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 21-23,system 100 further comprises pivoting-arm actuator 188, operativelycoupled to pivoting arm 152 and configured to actively control arotational position of pivoting arm 152 relative to delivery guide 112as delivery guide 112 moves relative to surface 114. The precedingsubject matter of this paragraph characterizes example 60 of the presentdisclosure, wherein example 60 also includes the subject matteraccording to example 59, above.

Pivoting-arm actuator 188 provides for selective pivoting of pivotingarm 152 and thus of source 116 relative to delivery guide 112.Accordingly, source 116 may be selectively positioned to delivery curingenergy 118 to portion 124 of segment 120 as delivery guide 112 moves,including as it changes directions, relative to surface 114 and/or viceversa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 21-23,pivoting-arm actuator 188 is configured to actively coordinate therotational position of pivoting arm 152 with movement of delivery guide112 relative to surface 114. The preceding subject matter of thisparagraph characterizes example 61 of the present disclosure, whereinexample 61 also includes the subject matter according to example 60,above.

Accordingly, source 116 may be selectively and actively positioned todelivery curing energy 118 to portion 124 of segment 120 as deliveryguide 112 moves, including as it changes directions, relative to surface114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 21-26,source 116 of curing energy 118 is configured to trail delivery guide112 when delivery guide 112 moves relative to surface 114. The precedingsubject matter of this paragraph characterizes example 62 of the presentdisclosure, wherein example 62 also includes the subject matteraccording to any one of examples 11-61, above.

By trailing delivery guide 112, source 116 is selectively positioned todeliver curing energy 118 to portion 124 of segment 120 directlyfollowing portion 124 exiting delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 6, 7, and19, source 116 of curing energy 118 is configured to deliver ring 148 ofcuring energy 118, intersecting segment 120 of continuous flexible line106. The preceding subject matter of this paragraph characterizesexample 63 of the present disclosure, wherein example 63 also includesthe subject matter according to any one of examples 11-23, above.

When ring 148 of curing energy 118 intersects segment 120, ring 148ensures that curing energy 118 is delivered to portion 124 regardless ofa direction that segment 120 is exiting delivery guide 112 as deliveryguide 112 moves relative to surface 114 and/or vice versa.

Ring 148 of curing energy 118 may be defined by any suitable processand/or structure. For example, with reference to FIG. 6, and asdiscussed herein, delivery guide 112 may comprise curing-energy passage146, and source 116 of curing energy 118 may be configured to delivercuring energy 118 through curing-energy passage 146 such that curingenergy 118 defines ring 148. Additionally or alternatively, withreference to FIG. 19, as also discussed herein, energy source 116 maycomprise at least one galvanometer mirror-positioning system 150 that isconfigured to deliver ring 148 of curing energy 118 to portion 124 ofsegment 120.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 5-7,delivery guide 112 further comprises line passage 154, through whichcontinuous flexible line 106 is delivered to print path 122, andcuring-energy passage 146. Source 116 of curing energy 118 is configuredto deliver curing energy 118 through curing-energy passage 146 at leastto portion 124 of segment 120 of continuous flexible line 106.Curing-energy passage 146 is optically isolated from line passage 154.The preceding subject matter of this paragraph characterizes example 64of the present disclosure, wherein example 64 also includes the subjectmatter according to any one of examples 11-23 and 63, above.

A system according to example 64 provides for precise direction ofcuring energy 118 to portion 124 as continuous flexible line 106 isexiting delivery guide 112. Moreover, by being optically isolated fromguide line passage 154, curing-energy passage 146 restricts curingenergy 118, when in the form of light, from contacting continuousflexible line 106 before continuous flexible line 106 exits deliveryguide 112.

According to example 64 (referring, e.g., to FIG. 6), curing-energypassage 146 may encircle guide line passage 154 and may have a circularoutlet around guide outlet 206 of guide line passage 154, such that theexit of curing energy 118 from curing-energy passage 146 results in ring148 of curing energy 118, such as according to example 63 herein.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 19, source116 of curing energy 118 is not configured to move with delivery guide112. The preceding subject matter of this paragraph characterizesexample 65 of the present disclosure, wherein example 65 also includesthe subject matter according to any one of examples 11-23, above.

Such an example of system 100 may provide for a less cumbersome assemblyassociated with delivery guide 112, permitting delivery guide 112 tomore easily make micro-movements and turns, or angle changes, relativeto surface 114 and/or vice versa, such as based on the configuration ofcomposite part 102, and desired properties thereof, being manufactured.

FIG. 19 provides an example of system 100, with energy source 116comprising two galvanometer mirror-positioning systems 150 that arestatic relative to delivery guide 112 as delivery guide 112 movesrelative to surface 114, but with galvanometer mirror-positioningsystems 150 configured to deliver curing energy 118 to portion 124 ofsegment 120 of continuous flexible line 106 as it exits delivery guide112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 19, source116 of curing energy 118 comprises at least one galvanometermirror-positioning system 150, configured to deliver curing energy 118at least to portion 124 of segment 120 of continuous flexible line 106responsive to movement of delivery guide 112 relative to surface 114.The preceding subject matter of this paragraph characterizes example 66of the present disclosure, wherein example 66 also includes the subjectmatter according to any one of examples 11-16, above.

In other words, one or more galvanometer mirror-positioning systems 150may actively direct curing energy 118 at portion 124 of segment 120 ascontinuous flexible line 106 exits delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 4, source116 of curing energy 118 is configured to partially cure first layer 140of segment 120 of continuous flexible line 106 as at least a portion offirst layer 140 is being deposited by delivery guide 112 against surface114 and to further cure first layer 140 and to partially cure secondlayer 142 as second layer 142 is being deposited by delivery guide 112against first layer 140. The preceding subject matter of this paragraphcharacterizes example 67 of the present disclosure, wherein example 67also includes the subject matter according to any one of examples 11-66,above.

By only partially curing first layer 140 as first layer 140 is beingdeposited, first layer 140 may remain tacky, or sticky, therebyfacilitating adhesion of second layer 142 against first layer 140 assecond layer 142 is deposited against first layer 140. Then, first layer140 is further cured as second layer 142 is being partially cured fordeposition of a subsequent layer against second layer 142, and so forth.

By further curing first layer 140, it is meant that first layer 140 maybe fully cured or less than fully cured. For example, in someapplications, it may be desirable for a less than full cure of compositepart 102 during manufacture by system 100 to permit for subsequent workon composite part 102 before an entirety of composite part 102 is fullycured, such as with a process separate from system 100. For example,composite part 102 may be baked, heated, and/or placed in an autoclavefor final curing.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 10-14,21, and 23, system 100 further comprises compactor 138, operativelycoupled to delivery guide 112. Compactor 138 is configured to impart acompaction force at least to section 180 of segment 120 of continuousflexible line 106 after segment 120 of continuous flexible line 106exits delivery guide 112. The preceding subject matter of this paragraphcharacterizes example 68 of the present disclosure, wherein example 68also includes the subject matter according to any one of examples 1-10,above.

Compactor 138 compacts adjacent layers of continuous flexible line 106that have been deposited by delivery guide 112 along print path 122.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 10-12,21, and 23, compactor 138 comprises compaction roller 182, havingcompaction-roller surface 184 that is configured to roll over at leastsection 180 of segment 120 of continuous flexible line 106 after segment120 of continuous flexible line 106 exits delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 69 ofthe present disclosure, wherein example 69 also includes the subjectmatter according to example 68, above.

Compaction roller 182, compared to alternative examples of compactor138, may reduce the axial movement of thermosetting-epoxy-resincomponent 110 along segment 120 during compaction. Additionally,compared to alternative examples of compactor 138, compaction roller 182may provide a more desirable normal, or perpendicular, component of thecompaction force.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 10,compaction-roller surface 184 is textured. The preceding subject matterof this paragraph characterizes example 70 of the present disclosure,wherein example 70 also includes the subject matter according to example69, above.

When compaction-roller surface 184 is textured, compaction-rollersurface 184 imparts a texture to segment 120 or abrades segment 120,providing it with an increased surface area for better adhesion of asubsequent layer of continuous flexible line 106 deposited against it.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 11,compaction-roller surface 184 is shaped to impart a predeterminedcross-sectional shape at least to section 180 of segment 120 ofcontinuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. The preceding subject matter of thisparagraph characterizes example 71 of the present disclosure, whereinexample 71 also includes the subject matter according to any one ofexamples 69 or 70, above.

It may be desirable, in some applications, to impart a predeterminedcross-sectional shape to continuous flexible line 106 as it is beingdeposited by delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 13,compactor 138 comprises compaction wiper 185, having wiper drag surface186 that is configured to drag against at least section 180 of segment120 of continuous flexible line 106 after segment 120 of continuousflexible line 106 exits delivery guide 112. The preceding subject matterof this paragraph characterizes example 72 of the present disclosure,wherein example 72 also includes the subject matter according to example68, above.

Compaction wiper 185, compared to alternative examples of compactor 138,may increase the axial movement of thermosetting-epoxy-resin component110 along segment 120 during compaction.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 13, wiperdrag surface 186 is textured. The preceding subject matter of thisparagraph characterizes example 73 of the present disclosure, whereinexample 73 also includes the subject matter according to example 72,above.

When drag surface 186 is textured, drag surface 186 imparts a texture tosegment 120 or abrades segment 120, providing it with an increasedsurface area for better adhesion of a subsequent layer of continuousflexible line 106 deposited against it.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 13, wiperdrag surface 186 is shaped to impart a predetermined cross-sectionalshape to segment 120 of continuous flexible line 106 after segment 120of continuous flexible line 106 exits delivery guide 112. The precedingsubject matter of this paragraph characterizes example 74 of the presentdisclosure, wherein example 74 also includes the subject matteraccording to any one of examples 72 or 73, above.

As mentioned, it may be desirable, in some applications, to impart apredetermined cross-sectional shape to continuous flexible line 106 asit is being deposited by delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 12, 21,and 23, compactor 138 is biased toward section 180 of segment 120 ofcontinuous flexible line 106. The preceding subject matter of thisparagraph characterizes example 75 of the present disclosure, whereinexample 75 also includes the subject matter according to any one ofexamples 68-74, above.

By being biased toward section 180, compactor 138 imparts a desiredcompaction force against section 180.

Compactor 138 may be biased toward section 180, such as by spring 181 orother biasing member.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 12, 21,and 23, compactor 138 is rotatable relative to delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 76 ofthe present disclosure, wherein example 76 also includes the subjectmatter according to any one of examples 68-75, above.

By being rotatable relative to delivery guide 112, compactor 138 may beselectively positioned to impart its compaction force against section180 of segment 120 as delivery guide 112 moves, including as it changesdirections, relative to surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 12, 21,and 23, compactor 138 is configured to trail delivery guide 112 whendelivery guide 112 moves relative to surface 114. The preceding subjectmatter of this paragraph characterizes example 77 of the presentdisclosure, wherein example 77 also includes the subject matteraccording to any one of examples 68-76, above.

By trailing delivery guide 112, compactor 138 is selectively positionedto impart its compaction force against section 180 of segment 120directly following section 180 exiting delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 21 and23, system 100 further comprises pivoting arm 152, coupled relative todelivery guide 112 such that pivoting arm 152 trails delivery guide 112as delivery guide 112 moves relative to surface 114. Compactor 138 iscoupled to pivoting arm 152. The preceding subject matter of thisparagraph characterizes example 78 of the present disclosure, whereinexample 78 also includes the subject matter according to any one ofexamples 68-77, above.

Pivoting arm 152 provides for selective pivoting of compactor 138relative to delivery guide 112. Accordingly, compactor 138 may beselectively positioned to impart its compaction force against section180 of segment 120 as delivery guide 112 moves, including as it changesdirections, relative to surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 21 and23, system 100 further comprises pivoting-arm actuator 188, operativelycoupled to pivoting arm 152 and configured to actively control arotational position of pivoting arm 152 relative to delivery guide 112as delivery guide 112 moves relative to surface 114. The precedingsubject matter of this paragraph characterizes example 79 of the presentdisclosure, wherein example 79 also includes the subject matteraccording to example 78, above.

Pivoting-arm actuator 188 provides for selective pivoting of pivotingarm 152 and thus of compactor 138 relative to delivery guide 112.Accordingly, compactor 138 may be selectively positioned to impart itscompaction force against section 180 of segment 120 as delivery guide112 moves, including as it changes directions, relative to surface 114and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 21 and23, pivoting-arm actuator 188 is configured to actively coordinate therotational position of pivoting arm 152 with movement of delivery guide112 relative to surface 114. The preceding subject matter of thisparagraph characterizes example 80 of the present disclosure, whereinexample 80 also includes the subject matter according to example 79,above.

Accordingly, compactor 138 may be selectively and actively positioned toimpart its compaction force against section 180 of segment 120 asdelivery guide 112 moves, including as it changes directions, relativeto surface 114 and/or vice versa.

Referring to FIG. 14, compactor 138 comprises skirt 190, coupled todelivery guide 112. Skirt 190 comprises skirt drag surface 192 that ispositioned to drag against at least section 180 of segment 120 ofcontinuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. The preceding subject matter of thisparagraph characterizes example 81 of the present disclosure, whereinexample 81 also includes the subject matter according to examples 68,above.

Skirt 190 extends from delivery guide 112 and circumferentially aroundoutlet 206. Accordingly, regardless of a direction of movement ofdelivery guide 112 relative to surface 114, and/or vice versa, skirt 90is positioned to compact section 180 of segment 120 of continuousflexible line 106 as it is being deposited.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises surface roughener 144, operatively coupled todelivery guide 112. Surface roughener 144 is configured to abrade atleast section 194 of segment 120 of continuous flexible line 106 aftersegment 120 of continuous flexible line 106 exits delivery guide 112.The preceding subject matter of this paragraph characterizes example 82of the present disclosure, wherein example 82 also includes the subjectmatter according to any one of examples 1-10 and 68-81, above.

Surface roughener 144 abrades section 194, providing it with anincreased surface area for better adhesion of a subsequent layerdeposited against it.

Referring generally to FIG. 1, surface roughener 144 comprisesroughening roller 196, having roughening roller surface 198 that isconfigured to rotationally abrade at least section 194 of segment 120 ofcontinuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. The preceding subject matter of thisparagraph characterizes example 83 of the present disclosure, whereinexample 83 also includes the subject matter according to example 82,above.

Roughening roller 196, compared to alternative examples of surfaceroughener 144, may reduce the axial movement ofthermosetting-epoxy-resin component 110 along segment 120 duringabrasion thereof. Moreover, roughing roller surface 198, by being heatedby conductive heat source 254 and rolling against segment 120 mayprovide for efficient heat transfer, and thus curing, of section 194.

Referring generally to FIG. 1, roughening roller surface 198 is shapedto impart a predetermined cross-sectional shape to segment 120 ofcontinuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. The preceding subject matter of thisparagraph characterizes example 84 of the present disclosure, whereinexample 84 also includes the subject matter according to example 83,above.

It may be desirable, in some applications, to impart a predeterminedcross-sectional shape to continuous flexible line 106 as it is beingdeposited by delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21,surface roughener 144 comprises roughening drag surface 200 that isconfigured to translationally abrade at least section 194 of segment 120of continuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. The preceding subject matter of thisparagraph characterizes example 85 of the present disclosure, whereinexample 85 also includes the subject matter according to example 82,above.

Roughening drag surface 200, compared to alternative examples of surfaceroughener 144, may increase the axial movement ofthermosetting-epoxy-resin component 110 along segment 120 duringabrasion thereof.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21,surface roughener 144 is biased toward section 194 of segment 120 ofcontinuous flexible line 106 after segment 120 of continuous flexibleline 106 exits delivery guide 112. The preceding subject matter of thisparagraph characterizes example 86 of the present disclosure, whereinexample 86 also includes the subject matter according to any one ofexamples 82-85, above.

By being biased toward section 194, surface roughener 144 imparts adesired abrasion force against section 194.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21,surface roughener 144 is rotatable relative to delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 87 ofthe present disclosure, wherein example 87 also includes the subjectmatter according to any one of examples 82-86, above.

By being rotatable relative to delivery guide 112, surface roughener 144may be selectively positioned to abrade section 194 as delivery guide112 moves, including as it changes directions, relative to surface 114and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21,surface roughener 144 is configured to trail delivery guide 112 whendelivery guide 112 moves relative to surface 114. The preceding subjectmatter of this paragraph characterizes example 88 of the presentdisclosure, wherein example 88 also includes the subject matteraccording to any one of examples 82-87, above.

By trailing delivery guide 112, surface roughener 144 is selectivelypositioned to abrade section 194 directly following segment 120 exitingdelivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises pivoting arm 152, configured such that pivotingarm 152 trails delivery guide 112 as delivery guide 112 moves relativeto surface 114. Surface roughener 144 is coupled to pivoting arm 152.The preceding subject matter of this paragraph characterizes example 89of the present disclosure, wherein example 89 also includes the subjectmatter according to any one of examples 82-88, above.

By trailing delivery guide 112, surface roughener 144 is selectivelypositioned to abrade section 194 directly following segment 120 exitingdelivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises pivoting-arm actuator 188, operatively coupled topivoting arm 152 and configured to actively control a rotationalposition of pivoting arm 152 relative to delivery guide 112 as deliveryguide 112 moves relative to surface 114. The preceding subject matter ofthis paragraph characterizes example 90 of the present disclosure,wherein example 90 also includes the subject matter according to example89, above.

Pivoting-arm actuator 188 provides for selective pivoting of pivotingarm 152 and thus of surface roughener 144 relative to delivery guide112. Accordingly, surface roughener 144 may be selectively positioned toabrade section 194 as delivery guide 112 moves, including as it changesdirections, relative to surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21,pivoting-arm actuator 188 is configured to actively coordinate therotational position of pivoting arm 152 with movement of delivery guide112 relative to surface 114. The preceding subject matter of thisparagraph characterizes example 91 of the present disclosure, whereinexample 91 also includes the subject matter according to example 90,above.

Accordingly, surface roughener 144 may be selectively and activelypositioned to abrade section 194 as delivery guide 112 moves, includingas it changes directions, relative to surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises compactor 138. Surface roughener 144 is positionedto abrade at least section 194 of segment 120 of continuous flexibleline 106 following compaction of at least section 194 by compactor 138.The preceding subject matter of this paragraph characterizes example 92of the present disclosure, wherein example 92 also includes the subjectmatter according to any one of examples 82-91, above.

System 100 according to example 48 includes both compactor 138 andsurface roughener 144. By having surface roughener 144 positioned toabrade section 194 following compaction by compactor 138, the abrasionof section 194 is not hindered, or dulled, by a subsequent compactionthereof. Accordingly, abrasion of section 194 has an increased surfacearea for better adhesion of a subsequent layer deposited against it.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises debris inlet 202, configured to collect debrisresulting from abrading at least section 194 of segment 120 ofcontinuous flexible line 106 with surface roughener 144. The precedingsubject matter of this paragraph characterizes example 93 of the presentdisclosure, wherein example 93 also includes the subject matteraccording to any one of examples 82-92, above.

Collection by debris inlet 202 of debris that results from abrasion ofsection 194 by surface roughener 144, avoids unwanted, loose particlesof thermosetting-epoxy-resin component 110 becoming trapped betweenadjacent deposited layers of continuous flexible line 106 that mayotherwise result in unwanted properties of composite part 102.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises vacuum source 203, selectively communicativelycoupled with debris inlet 202. The preceding subject matter of thisparagraph characterizes example 94 of the present disclosure, whereinexample 94 also includes the subject matter according to example 93,above.

Vacuum source 202 draws air and debris from adjacent section 194 throughdebris inlet 202.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises pivoting arm 152, coupled relative to deliveryguide 112 such that pivoting arm 152 trails delivery guide 112 asdelivery guide 112 moves relative to surface 114. Debris inlet 202 isoperatively coupled to pivoting arm 152. The preceding subject matter ofthis paragraph characterizes example 95 of the present disclosure,wherein example 95 also includes the subject matter according to any oneof examples 93 or 94, above.

By being coupled to pivoting arm 152, debris inlet 202 is selectivelypositioned to collect debris directly from adjacent section 194 asdelivery guide 112 moves relative to surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises pivoting-arm actuator 188, operatively coupled topivoting arm 152 and configured to actively control a rotationalposition of pivoting arm 152 relative to delivery guide 112 as deliveryguide 112 moves relative to surface 114. The preceding subject matter ofthis paragraph characterizes example 96 of the present disclosure,wherein example 96 also includes the subject matter according to example95, above.

Pivoting-arm actuator 188, by actively controlling a rotational positionof pivoting arm 152 relative to delivery guide 112, ensures that debrisinlet 202 trails delivery guide 112 so that debris inlet 202 isselectively positioned to collect debris directly adjacent to section194 as delivery guide 112 moves relative to surface 114 and/or viceversa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21,pivoting-arm actuator 188 is configured to actively coordinaterotational position of pivoting arm 152 with movement of delivery guide112 relative to surface 114. The preceding subject matter of thisparagraph characterizes example 97 of the present disclosure, whereinexample 97 also includes the subject matter according to example 96,above.

Pivoting-arm actuator 188, by actively coordinating a rotationalposition of pivoting arm 152 relative to delivery guide 112, ensuresthat debris inlet 202 trails delivery guide 112 so that debris inlet 202is selectively positioned to collect debris directly adjacent to section194 as delivery guide 112 moves relative to surface 114 and/or viceversa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises pressurized-gas outlet 204, configured to dispersedebris, resulting from roughening of segment 120 of continuous flexibleline 106 by surface roughener 144, with a pressurized gas. The precedingsubject matter of this paragraph characterizes example 98 of the presentdisclosure, wherein example 98 also includes the subject matteraccording to any one of examples 82-97, above.

Dispersal by pressurized-gas outlet 204 of debris that results fromabrasion of section 194 by surface roughener 144, avoids unwanted, looseparticles of thermosetting-epoxy-resin component 110 becoming trappedbetween adjacent deposited layers of continuous flexible line 106 thatmay otherwise result in unwanted properties of composite part 102.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises pressurized-gas source 205, selectivelycommunicatively coupled with pressurized-gas outlet 204. The precedingsubject matter of this paragraph characterizes example 99 of the presentdisclosure, wherein example 99 also includes the subject matteraccording to example 98, above.

Pressurized-gas source 205 provides a source of the pressurized gas tobe delivered to section 194 via pressurized-gas outlet 204.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises pivoting arm 152, configured such that pivotingarm 152 trails delivery guide 112 as delivery guide 112 moves relativeto surface 114. Pressurized-gas outlet 204 is operatively coupled topivoting arm 152. The preceding subject matter of this paragraphcharacterizes example 100 of the present disclosure, wherein example 100also includes the subject matter according to any one of examples 98 or99, above.

By being coupled to pivoting arm 152, pressurized-gas outlet 204 isselectively positioned to collect debris directly from adjacent section194 as delivery guide 112 moves relative to surface 114 and/or viceversa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21, system100 further comprises pivoting-arm actuator 188, operatively coupled topivoting arm 152 and configured to actively control a rotationalposition of pivoting arm 152 relative to delivery guide 112 as deliveryguide 112 moves relative to surface 114. The preceding subject matter ofthis paragraph characterizes example 101 of the present disclosure,wherein example 101 also includes the subject matter according toexample 100, above.

Pivoting-arm actuator 188, by actively controlling a rotational positionof pivoting arm 152 relative to delivery guide 112, ensures thatpressurized-gas outlet 204 trails delivery guide 112 so thatpressurized-gas outlet 204 is selectively positioned to disperse debrisdirectly adjacent to section 194 as delivery guide 112 moves relative tosurface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 21,pivoting-arm actuator 188 is configured to actively coordinate therotational position of pivoting arm 152 with movement delivery guide 112relative to surface 114. The preceding subject matter of this paragraphcharacterizes example 102 of the present disclosure, wherein example 102also includes the subject matter according to example 101, above.

Pivoting-arm actuator 188, by actively coordinating a rotationalposition of pivoting arm 152 relative to delivery guide 112, ensuresthat pressurized-gas outlet 204 trails delivery guide 112 so thatpressurized-gas outlet 204 is selectively positioned to disperse debrisdirectly adjacent to section 194 as delivery guide 112 moves relative tosurface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 8 and21-27, feed mechanism 104 is coupled to delivery guide 112. Thepreceding subject matter of this paragraph characterizes example 103 ofthe present disclosure, wherein example 103 also includes the subjectmatter according to any one of examples 1-102, above.

Having feed mechanism 104 coupled to delivery guide 112 facilitates feedmechanism 104 being able to operatively push continuous flexible line106 through delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 8 and21-27, delivery guide 112 extends from feed mechanism 104. The precedingsubject matter of this paragraph characterizes example 104 of thepresent disclosure, wherein example 104 also includes the subject matteraccording to any one of examples 1-103, above.

By extending from feed mechanism 104, delivery guide 112 may bepositioned for selective deposition of continuous flexible line 106 in adesired location along print path 122.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 8 and27-29, delivery guide 112 comprises line passage 154 through whichcontinuous flexible line 106 is delivered to print path 122. Linepassage 154 of delivery guide 112 has inlet 170. Feed mechanism 104 isconfigured to push continuous flexible line 106 through line passage154. Feed mechanism 104 comprises support frame 156 and opposing rollers157, having respective rotational axes 159. Opposing rollers 157 arerotatably coupled to support frame 156. Opposing rollers 157 areconfigured to engage opposite sides of continuous flexible line 106.Opposing rollers 157 are configured to selectively rotate to pushcontinuous flexible line 106 through line passage 154. The precedingsubject matter of this paragraph characterizes example 105 of thepresent disclosure, wherein example 105 also includes the subject matteraccording to any one of examples 1-104, above.

Support frame 156 provides support for component parts of feed mechanism104, including opposing rollers 157. Opposing rollers 157, whenselectively rotated, act to frictionally engage continuous flexible line106, thereby feeding it between opposing rollers 157 and pushing it intoinlet 170 and through line passage 154.

Referring generally to FIG. 8 and particularly to, e.g., FIGS. 27 and28, opposing rollers 157 are in contact with each other. The precedingsubject matter of this paragraph characterizes example 106 of thepresent disclosure, wherein example 106 also includes the subject matteraccording to example 105, above.

Contact between opposing rollers 157 may ensure that opposing rollers157 roll together and avoid imparting an uneven torque that would bendor otherwise create an internal curved bias to continuous flexible line106 as it is drawn between the rollers. Additionally or alternatively,contact between opposing rollers 157 may permit for only one of opposingrollers 157 to be directly driven by a motor, while the other ofopposing rollers 157 simply rotates as a result of being engaged withthe driven roller.

Referring generally to FIG. 8 and particularly to, e.g., FIGS. 27 and28, each of opposing rollers 157 comprises circumferential channel 161,configured to contact a portion of continuous flexible line 106. Thepreceding subject matter of this paragraph characterizes example 107 ofthe present disclosure, wherein example 107 also includes the subjectmatter according to any one of examples 105 or 106, above.

Inclusion of circumferential channel 161 in each of opposing rollers 157thereby creates a passage through which continuous flexible line 106 mayextend and provides for a greater surface area of contact betweenopposing rollers 157 and continuous flexible line 106, therebyfacilitating continuous flexible line 106 being pushed into inlet 170and through line passage 154.

Referring generally to FIG. 8 and particularly to, e.g., FIGS. 27 and28, one of opposing rollers 157 comprises circumferential channel 161,configured to contact continuous flexible line 106. The precedingsubject matter of this paragraph characterizes example 108 of thepresent disclosure, wherein example 108 also includes the subject matteraccording to any one of examples 105 or 106, above.

As with example 107, inclusion of one circumferential channel 161creates a passage through which continuous flexible line 106 may extendand provides for a greater surface area of contact between opposingrollers 157 and continuous flexible line 106, thereby facilitatingcontinuous flexible line 106 being pushed into inlet 170 and throughline passage 154.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 27 and28, opposing rollers 157 are differently sized. The preceding subjectmatter of this paragraph characterizes example 109 of the presentdisclosure, wherein example 109 also includes the subject matteraccording to any one of examples 105-108, above.

Differently sized opposing rollers 157 may permit for efficientpackaging of feed mechanism 104. Additionally or alternatively,differently sized opposing rollers 157 may provide for a desired torquetransfer between driven roller 158 and idle roller 160.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 8,opposing rollers 157 are identically sized. The preceding subject matterof this paragraph characterizes example 110 of the present disclosure,wherein example 110 also includes the subject matter according to anyone of examples 105-108, above.

Identically sized opposing rollers 157 may permit for efficientpackaging of feed mechanism 104. Additionally or alternatively,identically sized opposing rollers 157 may provide for a desired torquetransfer between driven roller 158 and idle roller 160.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 8 and21-29, feed mechanism 104 further comprises motor 162, operativelycoupled at least to one of opposing rollers 157 and configured toselectively rotate at least one of opposing rollers 157. The precedingsubject matter of this paragraph characterizes example 111 of thepresent disclosure, wherein example 111 also includes the subject matteraccording to any one of examples 105-110, above.

Motor 162 provides a motive force for rotating opposing rollers 157 forfeed mechanism 104 to push continuous flexible line 106 through deliveryguide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 8 and27-29, opposing rollers 157 comprise driven roller 158, operativelycoupled to motor 162, and idle roller 160, biased toward driven roller158 to operatively engage opposing sides of continuous flexible line106. The preceding subject matter of this paragraph characterizesexample 112 of the present disclosure, wherein example 112 also includesthe subject matter according to example 111, above.

By having idle roller 160 biased toward driven roller 158, idle roller160 need not be directly driven by a motor for feed mechanism 104 topush continuous flexible line 106 through delivery guide 112. Instead,idle roller 160 is rotated by idle roller 160 being engaged with drivenroller 158 and/or by being engaged with continuous flexible line 106,which in turn is engaged with driven roller 158.

Idle roller 160 may be biased toward driven roller 158 by biasing member164, which may be a spring, such as a coil spring.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 8 and27-29, feed mechanism 104 further comprises rocker arm 169. Rocker arm169 is pivotally coupled to support frame 156. Idle roller 160 isrotationally coupled to rocker arm 169. Rocker arm 169 is biasedrelative to support frame 156 so that idle roller 160 is biased towarddriven roller 158. Rocker arm 169 is configured to selectively pivotidle roller 160 away from driven roller 158. The preceding subjectmatter of this paragraph characterizes example 113 of the presentdisclosure, wherein example 113 also includes the subject matteraccording to example 112, above.

Rocker arm 169 provides structure for a user to engage and pivot idleroller 160 away from driven roller 158 against the bias of biasingmember 164. Accordingly, a user may selectively pivot idle roller 160 tofacilitate initial insertion of continuous flexible line 106 betweenopposing rollers 157, such as during initial set-up of system 100 and/orto change continuous flexible line 106 during manufacture of compositepart 102.

As used herein, “to bias” means to continuously apply a force, which mayor may not have a constant magnitude.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 27-29,feed mechanism 104 further comprises rocker-arm adjuster 171, configuredto selectively adjust a force applied to rocker arm 169 to bias idleroller 160 toward driven roller 158. The preceding subject matter ofthis paragraph characterizes example 114 of the present disclosure,wherein example 114 also includes the subject matter according toexample 113, above.

Rocker-arm adjuster 171 permits a user to selectively adjust the biasingforce of idle roller 160 toward driven roller 158 and thus the forceapplied to continuous flexible line 106 between opposing rollers 157.For example, different magnitudes of force facilitate operation ofsystem 100 in connection with different material properties of differentconfigurations and/or different sizes of continuous flexible line 106that may be used by system 100.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 8, 27,and 28, delivery guide 112 further comprises first end portion 163,second end portion 165, and junction 167 between first end portion 163and second end portion 165. First end portion 163 is shaped to becomplementary to one of opposing rollers 157 and second end portion 165is shaped to be complementary to another of opposing rollers 157. Thepreceding subject matter of this paragraph characterizes example 115 ofthe present disclosure, wherein example 115 also includes the subjectmatter according to any one of examples 105-114, above.

Having first end portion 163 and second end portion 165 complementarywith opposing rollers 157, delivery guide 112 may be positioned in veryclose proximity to opposing rollers 157. Accordingly, when feedmechanism 104 pushes continuous flexible line 106 into and throughdelivery guide 112, continuous flexible line 106 is less likely tobunch, kink, clog, or otherwise mis-feed from feed mechanism 104 todelivery guide 112.

Referring to FIG. 8, shortest distance D between junction 167 and plane173, containing respective rotational axes 159 of opposing rollers 157,is less than a radius of a smallest one of opposing rollers 157. Thepreceding subject matter of this paragraph characterizes example 116 ofthe present disclosure, wherein example 116 also includes the subjectmatter according to example 115, above.

Again, having delivery guide 112 in close proximity to opposing rollers157, such as with junction 167 within distance D of plane 173,continuous flexible line 106 operatively may be pushed into and throughdelivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 8, 27,and 28, junction 167 comprises an edge. The preceding subject matter ofthis paragraph characterizes example 117 of the present disclosure,wherein example 117 also includes the subject matter according to anyone of examples 115 or 116, above.

When junction 167 comprises an edge, the edge may be positioned in veryclose proximity to the interface between opposing rollers 157 and theinterface between opposing rollers 157 and continuous flexible line 106.

In some examples, the edge may be linear. In some examples, the edge maybe a sharp edge. In some examples, the edge may be a rounded edge.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 8, 27,and 28, feed mechanism 104 further comprises scraper 172 in contact withat least one of opposing rollers 157 to remove residue ofthermosetting-epoxy-resin component 110 produced by the engagementbetween opposing rollers 157 and continuous flexible line 106 asopposing rollers 157 rotate to selectively translate continuous flexibleline 106 to push continuous flexible line 106 through line passage 154.The preceding subject matter of this paragraph characterizes example 118of the present disclosure, wherein example 118 also includes the subjectmatter according to any one of examples 105-117, above.

Scraper 172 removes residue of thermosetting-epoxy-resin component 110from opposing rollers 157 to ensure that resin does not build up onopposing rollers 157 and hinder operation of feed mechanism 104.

Scraper 172 may take any suitable form to operatively or remove, orscrape, resin from opposing rollers 157. For example, with reference toFIGS. 27 and 28, scraper 172 may be a rectangular, or other, projectionthat extends in close proximity to one of opposing rollers 157, such aswithin 3 mm, 2 mm, 1 mm, 0.5 mm, or that extends to physically engageone of opposing rollers 157. More specifically, as seen in FIGS. 27 and28, scraper 172 may extend adjacent to a region of opposing rollers 157where opposing rollers engage continuous flexible line 106.

Referring to FIG. 9, at least one of opposing rollers 157 comprisescircumferential channel 161, configured to contact continuous flexibleline 106. Scraper 172 comprises projection 175, configured to removefrom circumferential channel 161 the residue ofthermosetting-epoxy-resin component 110 produced by the engagementbetween circumferential channel 161 and continuous flexible line 106 asopposing rollers 157 rotate to selectively translate continuous flexibleline 106 to push continuous flexible line 106 through line passage 154.The preceding subject matter of this paragraph characterizes example 119of the present disclosure, wherein example 119 also includes the subjectmatter according to example 118, above.

In examples of opposing rollers 157 that include circumferential channel161, scraper 172 having projection 175 extending therein facilitates thescraping, or removal, of any residue of thermosetting-epoxy-resincomponent 110 produced by engagement between opposing rollers 157 andcontinuous flexible line 106.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 8, 27,and 28, feed mechanism 104 further comprises collection reservoir 174,coupled to support frame 156. Collection reservoir 174 is configured tocollect the residue of thermosetting-epoxy-resin component 110 removedby scraper 172. The preceding subject matter of this paragraphcharacterizes example 120 of the present disclosure, wherein example 120also includes the subject matter according to any one of examples 118 or119, above.

As mentioned, collection reservoir 174 collects residue that is removedby scraper 172. Accordingly, the residue does not interfere with othercomponents of feed mechanism 104 and does not result in unwantedparticles hindering the manufacture of composite part 102. Moreover,collection reservoir 174 may be selectively emptied by a user, such aswhen full or at the end of a process performed by system 100.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 15-18,21, 30, and 31, delivery guide 112 comprises line passage 154 throughwhich continuous flexible line 106 is delivered to print path 122 andline passage 154 comprises outlet 206. System 100 further comprisescutter 208, configured to selectively cut continuous flexible line 106adjacent to outlet 206. The preceding subject matter of this paragraphcharacterizes example 121 of the present disclosure, wherein example 121also includes the subject matter according to any one of examples 1-120,above.

Inclusion of cutter 208 permits for the selective stopping and startingof delivery of continuous flexible line 106 by delivery guide 112. Byhaving cutter 208 configured to cut continuous flexible line 106adjacent to outlet 206, continuous flexible line 106 may be cut prior tobeing at least partially cured by curing energy 118 and while continuousflexible line 106 is not yet in contact with, and optionally compactedagainst, a prior deposited layer of continuous flexible line 106. Inother words, access to an entirety of the circumference of continuousflexible line 106 by cutter 208 is permitted.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 15-17,21, 30, and 31, cutter 208 comprises at least one blade 210, movablerelative to delivery guide 112. The preceding subject matter of thisparagraph characterizes example 122 of the present disclosure, whereinexample 122 also includes the subject matter according to example 121,above.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 15, cutter208 is iris diaphragm 212. The preceding subject matter of thisparagraph characterizes example 123 of the present disclosure, whereinexample 123 also includes the subject matter according to any one ofexamples 121 or 122, above.

Iris diaphragm 212 enables cutting of continuous flexible line 106 frommultiple sides of continuous flexible line 106. Accordingly, across-sectional profile of continuous flexible line 106 may be lessdeformed by cutter 208 than may otherwise result from other examples ofcutter 208.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 15 and17, cutter 208 is positioned within delivery guide 112. The precedingsubject matter of this paragraph characterizes example 124 of thepresent disclosure, wherein example 124 also includes the subject matteraccording to any one of examples 121-123, above.

Positioning of cutter 208 within delivery guide 112 provides for acompact assembly of system 100, such that cutter 208 does not hindermovement of delivery guide relative to surface 114 and/or vice versa.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 18, cutter208 comprises cutting laser 213. The preceding subject matter of thisparagraph characterizes example 125 of the present disclosure, whereinexample 125 also includes the subject matter according to example 121,above.

Use of cutting laser 213 to cut continuous flexible line 106 facilitatesprecision cutting of continuous flexible line 106 at a desired locationduring manufacture of composite part 102.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 18, cutter208 further comprises at least one galvanometer mirror-positioningsystem 214, configured to direct cutting laser 213 to selectively cutcontinuous flexible line 106 adjacent to outlet 206. The precedingsubject matter of this paragraph characterizes example 126 of thepresent disclosure, wherein example 126 also includes the subject matteraccording to example 125, above.

In other words, one or more galvanometer mirror-positioning systems 214may actively direct cutting laser 213 at continuous flexible line 106 asit exits delivery guide 112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 20, system100 further comprises drive assembly 216, operatively coupled at leastto one of delivery guide 112 or surface 114 and configured tooperatively and selectively move at least one of delivery guide 106 orsurface 114 relative to another. The preceding subject matter of thisparagraph characterizes example 127 of the present disclosure, whereinexample 127 also includes the subject matter according to any one ofexamples 1-126, above.

Drive assembly 216 facilitates the relative movement between deliveryguide 112 and surface 114 so that composite part 102 is manufacturedfrom continuous flexible line 106 as it is deposited via delivery guide112.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 20, driveassembly 216 comprises X-axis drive 217, Y-axis drive 219, and Z-axisdrive 215, at least one of which is operatively coupled at least to oneof delivery guide 112 or surface 114. The preceding subject matter ofthis paragraph characterizes example 128 of the present disclosure,wherein example 128 also includes the subject matter according toexample 127, above.

A system according to example 128 provides for three-dimensionalrelative movement between delivery guide 112 and surface 114.

Referring to FIG. 1, drive assembly 216 comprises robotic arm 218. Thepreceding subject matter of this paragraph characterizes example 129 ofthe present disclosure, wherein example 129 also includes the subjectmatter according to any one of examples 127 or 128, above.

Use of robotic arm 218 to operatively and selectively move deliveryguide 112 relative to surface 114 and/or vice versa permits for multipledegrees of freedom and the manufacture of complex three-dimensionalcomposite parts 102.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 20, driveassembly 216 is configured to operatively and selectively move at leastone of delivery guide 112 or surface 114 orthogonally in threedimensions relative to another. The preceding subject matter of thisparagraph characterizes example 130 of the present disclosure, whereinexample 130 also includes the subject matter according to any one ofexamples 127-129, above.

A system according to example 130 may manufacture composite part 102 inthree dimensions.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 20, driveassembly 216 is configured to operatively and selectively move at leastone of delivery guide 112 or surface 114 in three dimensions with atleast three degrees of freedom relative to another. The precedingsubject matter of this paragraph characterizes example 131 of thepresent disclosure, wherein example 131 also includes the subject matteraccording to any one of examples 127-129, above.

A system according to example 131 may manufacture complexthree-dimensional composite parts 102.

Referring generally to FIGS. 1 and 36, drive assembly 216 is configuredto operatively and selectively move at least one of delivery guide 112or surface 114 in three dimensions with at least six degrees of freedomrelative to another. The preceding subject matter of this paragraphcharacterizes example 132 of the present disclosure, wherein example 132also includes the subject matter according to any one of examples127-129, above.

A system according to example 132 may manufacture complexthree-dimensional composite parts 102.

Referring generally to FIGS. 1 and 36, drive assembly 216 is configuredto operatively and selectively move at least one of delivery guide 112or surface 114 in three dimensions with at least nine degrees of freedomrelative to another. The preceding subject matter of this paragraphcharacterizes example 133 of the present disclosure, wherein example 133also includes the subject matter according to any one of examples127-129, above.

A system according to example 133 may manufacture complexthree-dimensional composite parts 102.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 36, driveassembly 216 is configured to operatively and selectively move at leastone of delivery guide 112 or surface 114 in three dimensions with atleast twelve degrees of freedom relative to another. The precedingsubject matter of this paragraph characterizes example 134 of thepresent disclosure, wherein example 134 also includes the subject matteraccording to any one of examples 127-129, above.

A system according to example 134 may manufacture complexthree-dimensional composite parts 102.

With reference to FIG. 36, a schematic illustration according to example134 is presented, with linear translational elements 290 and rotationalelements 292 providing twelve degrees of freedom between delivery guide112 and surface 114, and with controller 294 being operativelycommunicatively coupled to linear translational elements 290 androtational elements 292.

Referring to FIG. 1, system 100 further comprises shielding-gas outlet220, configured to at least partially protect segment 120 of continuousflexible line 106 from oxidation by delivering shielding gas 221 tosegment 120 of continuous flexible line 106 after segment 120 exitsdelivery guide 112. The preceding subject matter of this paragraphcharacterizes example 135 of the present disclosure, wherein example 135also includes the subject matter according to any one of examples 1-134,above.

Inclusion of shielding-gas outlet 220 and delivery of shielding gas 221therefrom to segment 120 restricts oxidation of continuous flexible line106 prior to being further cured and/or during further curing by source116.

Referring to FIG. 1, system 100 further comprises shielding-gas source222, selectively communicatively coupled with shielding-gas outlet 220.The preceding subject matter of this paragraph characterizes example 136of the present disclosure, wherein example 136 also includes the subjectmatter according to example 135, above.

Shielding-gas source 222 provides a source of shielding gas 221 to bedelivered to segment 120 via shielding-gas outlet 220.

Referring to FIG. 1, system 100 further comprises pivoting arm 152,coupled relative to delivery guide 112 such that pivoting arm 152 trailsdelivery guide 112 as at least one of delivery guide 112 or surface 114moves relative to another. Shielding-gas outlet 220 is operativelycoupled to pivoting arm 152. The preceding subject matter of thisparagraph characterizes example 137 of the present disclosure, whereinexample 137 also includes the subject matter according to any one ofexamples 135 or 136, above.

By being coupled to pivoting arm 152, shielding-gas outlet 220 isselectively positioned to deliver shielding gas 221 to segment 120 asdelivery guide 112 moves relative to surface 114 and/or vice versa.

Referring to FIG. 1, system 100 further comprises defect detector 224,configured to detect defects in segment 120 of continuous flexible line106 after segment 120 of continuous flexible line 106 exits deliveryguide 112. The preceding subject matter of this paragraph characterizesexample 138 of the present disclosure, wherein example 138 also includesthe subject matter according to any one of examples 1-137, above.

Detection of defects in segment 120 permits for selective scrapping ofcomposite parts 102 having defects prior to completion of compositeparts 102. Accordingly, less material may be wasted. Moreover, defectsthat otherwise would be hidden from view by various types of defectdetectors may be detected by defect detector 224 prior to a subsequentlayer of continuous flexible line 106 obscuring, or hiding, the defectfrom view.

Referring to FIG. 1, defect detector 224 comprises optical detector 226or ultrasonic detector 227. The preceding subject matter of thisparagraph characterizes example 139 of the present disclosure, whereinexample 139 also includes the subject matter according to example 138,above.

In some applications, optical detector 226 may be well suited to detectdefects in segment 120 of continuous flexible line 106. In someapplications, ultrasonic detector 227 may be well suited to detectdefects in segment 120 of continuous flexible line 106.

Referring to FIG. 1, defect detector 224 comprises camera 228. Thepreceding subject matter of this paragraph characterizes example 140 ofthe present disclosure, wherein example 140 also includes the subjectmatter according to example 138, above.

Camera 228 may be well suited to detect defects in segment 120 ofcontinuous flexible line 106.

Referring to FIG. 1, system 100 further comprises controller 230 and oneor more of source 116 of curing energy 118; origin 126 of continuousflexible line 106; pivoting-arm actuator 188; compactor 138; surfaceroughener 144; motor 162; debris inlet 202; vacuum source 203,selectively communicatively coupled with debris inlet 202;pressurized-gas outlet 204; pressurized-gas source 205, selectivelycommunicatively coupled with pressurized-gas outlet 204; cutter 208;drive assembly 216; shielding-gas outlet 220; shielding-gas source 222,selectively communicatively coupled with shielding-gas outlet 220; anddefect detector 224. Controller 230 is programmed to selectively operateone or more of delivery guide 112, feed mechanism 104, source 116 ofcuring energy 118, origin 126 of continuous flexible line 106,pivoting-arm actuator 188, compactor 138, surface roughener 144, motor162, vacuum source 203, pressurized-gas source 205, cutter 208, driveassembly 216, shielding-gas source 222, or defect detector 224. Thepreceding subject matter of this paragraph characterizes example 141 ofthe present disclosure, wherein example 141 also includes the subjectmatter according to any one of examples 1-140, above.

Controller 230 controls the operation of various component parts ofsystem 100. For example, precise movement of delivery guide 112 and/orsurface 114 relative to each other may be controlled to manufacture adesired three-dimensional composite part 102. Precise pivoting ofpivoting arm 152 by pivoting-arm actuator 188 may be controlled toprecisely deliver a compaction force by compactor 138, to preciselydeliver curing energy 118, to precisely abrade continuous flexible line106 by surface roughener 144, and so forth. Additionally, operation ofvarious component parts may be selectively started and stopped bycontroller 230 during manufacture of composite part 102 to createdesired properties and configurations of composite part 102.

In FIG. 1, communication between controller 230 and various componentparts of system 100 is schematically represented by lightning bolts.Such communication may be wired and/or wireless in nature.

Controller 230 may include any suitable structure that may be adapted,configured, designed, constructed, and/or programmed to automaticallycontrol the operation of at least a portion of system 100. Asillustrative, non-exclusive examples, controller 230 may include and/orbe an electronic controller, a dedicated controller, a special-purposecontroller, a personal computer, a display device, a logic device,and/or a memory device. In addition, controller 230 may be programmed toperform one or more algorithms to automatically control the operation ofsystem 100. This may include algorithms that may be based upon and/orthat may cause controller 230 to direct system 100 to perform methods300 and 400 disclosed herein.

Referring generally to FIG. 1 and particularly to, e.g., FIG. 20, system100 further comprises frame 232 that supports feed mechanism 104 andsurface 114. The preceding subject matter of this paragraphcharacterizes example 142 of the present disclosure, wherein example 142also includes the subject matter according to any one of examples 1-141,above.

Frame 232 structurally supports feed mechanism 104 and surface 114 sothat feed mechanism 104 may operatively and selectively move deliveryguide 112 relative to surface 114 and/or vice versa.

Referring generally to FIG. 1, thermosetting-epoxy-resin component 110is configured to cure at a temperature between about 20° C. and about30° C. within a period greater than 5 minutes or to cure at atemperature greater than 150° C. within a period of less than 5 seconds.The preceding subject matter of this paragraph characterizes example 143of the present disclosure, wherein example 143 also includes the subjectmatter according to any one of examples 1-142, above.

Various thermosetting epoxy resins may be used forthermosetting-epoxy-resin component 110 and may be selected based on oneor more of desired properties prior to being fully cured, desiredproperties after being fully cured, desired curing properties, such asbased on length of time and/or temperatures required to fully cure, etc.The examples set forth in example 143 are illustrative andnon-exclusive, and other configurations of thermosetting-epoxy-resincomponent 110 may be used with system 100.

Referring generally to FIG. 1, threshold temperature is no greater than20° C., 15° C., 10° C., 5° C., 0° C., −50° C., −100° C., −150° C., −200°C., −200-−100° C., −100-0° C., −50-5° C., 5-20° C., 5-15° C., or 5-10°C. The preceding subject matter of this paragraph characterizes example144 of the present disclosure, wherein example 144 also includes thesubject matter according to any one of examples 1-143, above.

The threshold temperature associated with system 100 and cooling system234 may be selected based on a thermosetting epoxy resin being used forthermosetting-epoxy-resin component 110, and the examples set forth inexample 144 are illustrated and non-exclusive.

Referring, e.g., to FIGS. 1,2,3,8, and 20-23 and particularly to FIG.32, method 300 of additively manufacturing a composite part 102 isdisclosed. Method 300 comprises (block 302) pushing continuous flexibleline 106 through delivery guide 112. Continuous flexible line 106comprises non-resin component 108 and thermosetting-epoxy-resincomponent 110 that is partially cured. Method 300 also comprises (block304) depositing, via delivery guide 112, segment 120 of continuousflexible line 106 along print path 122. Method 300 further comprises(block 306) maintaining thermosetting-epoxy-resin component 110 of atleast continuous flexible line 106 being pushed through delivery guide112 below a threshold temperature prior to depositing segment 120 ofcontinuous flexible line 106 along print path 122. The preceding subjectmatter of this paragraph characterizes example 145 of the presentdisclosure.

Method 300 therefore may be performed to manufacture composite parts 102from at least a composite material that includes non-resin component 108and thermosetting-epoxy-resin component 110. Becausethermosetting-epoxy-resin component 110 is maintained below a thresholdtemperature prior to being deposited along print path 122, athermosetting epoxy resin may be selected for thermosetting-epoxy-resincomponent 110 to have desired properties. Moreover, method 300 may beperformed to manufacture composite parts 102 with continuous flexibleline 106 being oriented in desired and/or predetermined orientationsthroughout composite part 102, such as to define desired properties ofcomposite part 102.

Method 300 may be performed by system 100.

Referring to FIG. 32, (block 308) the threshold temperature is nogreater than 20° C., 15° C., 10° C., 5° C., 0° C., −50° C., −100° C.,−150° C., −200° C., −200-−100° C., −100-0° C., −50-5° C., 5-20° C.,5-15° C., or 5-10° C. The preceding subject matter of this paragraphcharacterizes example 146 of the present disclosure, wherein example 146also includes the subject matter according to example 145, above.

The threshold temperature associated with method 300 may be selectedbased on a thermosetting epoxy resin being used forthermosetting-epoxy-resin component 110, and the examples set forth inexample 146 are illustrated and non-exclusive.

Referring to FIG. 32, (block 310) thermosetting-epoxy-resin component110 is configured to cure at a temperature between about 20° C. andabout 30° C. within a period greater than 5 minutes or to cure at atemperature greater than 150° C. within a period of less than 5 seconds.The preceding subject matter of this paragraph characterizes example 147of the present disclosure, wherein example 147 also includes the subjectmatter according to any one of examples 145 or 146, above.

Various thermosetting epoxy resins may be used forthermosetting-epoxy-resin component 110 and may be selected based on oneor more of desired properties prior to being fully cured, desiredproperties after being fully cured, desired curing properties, such asbased on length of time and/or temperatures required to fully cure, etc.The examples set forth in example 147 are illustrative andnon-exclusive, and other configurations of thermosetting-epoxy-resincomponent 110 may be used in connection with method 300.

Referring, e.g., to FIGS. 1-3 and particularly to FIG. 32, (block 312)continuous flexible line 106 comprises a prepreg composite material. Thepreceding subject matter of this paragraph characterizes example 148 ofthe present disclosure, wherein example 148 also includes the subjectmatter according to any one of examples 145-147, above.

Because continuous flexible line 106 comprises a prepreg compositematerial, the component parts of continuous flexible line 106, namelynon-resin component 108 and thermosetting-epoxy-resin component 110, maybe deposited along print path 122 as a continuous source material forcomposite part 102. Moreover, as composite part 102 is being formed, thenatural tackiness of the prepreg composite material may facilitateadhesion between layers being deposited by method 300.

Referring, e.g., to FIGS. 2 and 3 and particularly to FIG. 32, (block314) non-resin component 108 comprises one or more of a fiber, a carbonfiber, a glass fiber, a synthetic organic fiber, an aramid fiber, anatural fiber, a wood fiber, a boron fiber, a silicon-carbide fiber, anoptical fiber, a fiber bundle, a fiber tow, a fiber weave, a wire, ametal wire, a conductive wire, or a wire bundle. The preceding subjectmatter of this paragraph characterizes example 149 of the presentdisclosure, wherein example 149 also includes the subject matteraccording to any one of examples 145-148, above.

Inclusion of a fiber or fibers in continuous flexible line 106 permitsfor selecting desired properties of composite part 102. Moreover,selection of specific materials of fibers and/or selection of specificconfigurations of fibers (e.g., a bundle, a tow, and/or a weave) maypermit for precise selection of desired properties of composite part102. Example properties of composite parts 102 include strength,stiffness, flexibility, ductility, hardness, electrical conductivity,thermal conductivity, etc. Non-resin component 108 is not limited to theidentified examples, and other types of non-resin component 108 may beused.

FIG. 2 schematically represents continuous flexible line 106 with asingle fiber as non-resin component 108 within a matrix ofthermosetting-epoxy-resin component 110. FIG. 3 schematically representscontinuous flexible 106 with more than one fiber as non-resin component108 within a matrix of thermosetting-epoxy-resin component 110.

Referring, e.g., to FIGS. 1 and 4 and particularly to FIG. 32, (block304) depositing segment 120 of continuous flexible line 106 along printpath 122 comprises (block 316) layering continuous flexible line 106against itself or a previously deposited segment 120 to additivelymanufacture composite part 102. The preceding subject matter of thisparagraph characterizes example 150 of the present disclosure, whereinexample 150 also includes the subject matter according to any one ofexamples 145-149, above.

By layering continuous flexible line 106 against itself or a previouslydeposited segment 120, a three-dimensional composite part 102 may bemanufactured by performance of method 300.

Accordingly, method 300 may be described as a 3-D printing method and/oras an additive manufacturing method.

Referring, e.g., to FIG. 1 and particularly to FIG. 32, (block 304)depositing segment 120 of continuous flexible line 106 along print path122 comprises (block 318) depositing continuous flexible line 106 in apredetermined pattern to selectively control one or more physicalcharacteristics of composite part 102. The preceding subject matter ofthis paragraph characterizes example 151 of the present disclosure,wherein example 151 also includes the subject matter according to anyone of examples 145-150, above.

By controlling one or more physical characteristics of composite part102, less overall material may be used and/or the size of a specificpart may be reduced when compared to a similar part manufactured by atraditional composite layup method.

For example, in contrast to composite parts constructed from multiplelayers of planar plies of composite material, composite part 102 may bemanufactured so that the orientation of continuous flexible line 106,and thus of non-resin component 108, results in desired properties. Asan example, if a part includes holes, continuous flexible line may bearranged generally in concentric circles or spiral around the holes,resulting in no or few interruptions to continuous flexible line 106 atthe boundary of the holes. As a result, the strength of the part may besignificantly greater around the hole than a similar part constructed bytraditional composite layup methods. In addition the part may be lesssubject to cracks and propagation thereof at the boundary of the holes.Moreover, because of the desired properties around the holes, theoverall thickness, volume, and/or mass of the part may be reduced whileachieving the desired properties, when compared to a similar partconstructed by traditional composite layup methods.

Referring, e.g., to FIG. 1 and particularly to FIG. 32, (block 320)physical characteristics include at least one of strength, stiffness,flexibility, ductility, or hardness. The preceding subject matter ofthis paragraph characterizes example 152 of the present disclosure,wherein example 152 also includes the subject matter according toexample 151, above.

Each of these physical characteristics may be selected for a particularpurpose. For example, in a composite part that when in use receives asignificant torque on a sub-part thereof compared to the remainder ofthe composite part, it may be desirable to have such sub-part less stiffand/or more flexible than other parts of the composite part.Additionally, it may be desirable to build more strength into a sub-partthan other parts of composite part 102 for various reasons depending ona specific application of composite part 102.

Referring, e.g., to FIGS. 1, 4-7, 12, 19, and 21-26 and particularly toFIG. 32, method 300 further comprises (block 322) delivering apredetermined or actively determined amount of curing energy 118 atleast to portion 124 of segment 120 of continuous flexible line 106 at acontrolled rate while advancing continuous flexible line 106 towardprint path 122 and after segment 120 of continuous flexible line 106 isdeposited along print path 122 to at least partially cure at leastportion 124 of segment 120 of continuous flexible line 106. Thepreceding subject matter of this paragraph characterizes example 153 ofthe present disclosure, wherein example 153 also includes the subjectmatter according to any one of examples 145-152, above.

As a result of delivering a predetermined or actively determined amountof curing energy 118 at a controlled rate, a desired level, or degree,of cure may be established with respect to portion 124 of segment 120 atany given time during manufacture of composite part 102. That is,composite part 102 may be cured at least partially in situ.Additionally, as discussed herein, in some examples, it may be desirableto cure one portion 124 greater than or less than another portion 124during manufacture of composite part 102.

Referring, e.g., to FIGS. 1 and 4 and particularly to FIG. 32, (block322) delivering the predetermined or actively determined amount ofcuring energy 118 at least to portion 124 of segment 120 of continuousflexible line 106 at the controlled rate comprises (block 324) partiallycuring first layer 140 of segment 120 of continuous flexible line 106 asfirst layer 140 is being deposited and further curing first layer 140 assecond layer 142 is being deposited against first layer 140. Thepreceding subject matter of this paragraph characterizes example 154 ofthe present disclosure, wherein example 154 also includes the subjectmatter according to example 153, above.

By only partially curing first layer 140 as first layer 140 is beingdeposited, first layer 140 may remain tacky, or sticky, therebyfacilitating adhesion of second layer 142 against first layer 140 assecond layer 142 is deposited against first layer 140. Then, first layer140 is further cured as second layer 142 is being partially cured fordeposition of a subsequent layer against second layer 142, and so forth.

Referring, e.g., to FIGS. 1 and 4 and particularly to FIG. 32, (block322) delivering the predetermined or actively determined amount ofcuring energy 118 at least to portion 124 of segment 120 of continuousflexible line 106 at the controlled rate comprises (block 326) partiallycuring first layer 140 of segment 120 of continuous flexible line 106 asfirst layer 140 is being deposited and fully curing first layer 140 assecond layer 142 is being deposited against first layer 140. Thepreceding subject matter of this paragraph characterizes example 155 ofthe present disclosure, wherein example 155 also includes the subjectmatter according to any one of examples 153 or 154, above.

Again, by only partially curing first layer 140 as first layer 140 isbeing deposited, first layer 140 may remain tacky, or sticky, therebyfacilitating adhesion of second layer 142 against first layer 140 assecond layer 142 is deposited against first layer 140. However,according to this example 155, first layer 140 is fully cured as secondlayer 142 is being partially cured.

Referring, e.g., to FIG. 1 and particularly to FIG. 32, (block 322)delivering the predetermined or actively determined amount of curingenergy 118 at least to portion 124 of segment 120 of continuous flexibleline 106 at the controlled rate comprises (block 328) curing less thanan entirety of composite part 102. The preceding subject matter of thisparagraph characterizes example 156 of the present disclosure, whereinexample 156 also includes the subject matter according to any one ofexamples 153-155, above.

In some applications, a less cured portion may be desirable so that itmay be subsequently worked on by a subsequent process, such as to removematerial and/or add a structural or other component to composite part102.

Referring, e.g., to FIG. 1 and particularly to FIG. 32, method 300further comprises (block 330) restrictively curing at least a portion ofcomposite part 102. The preceding subject matter of this paragraphcharacterizes example 157 of the present disclosure, wherein example 157also includes the subject matter according to any one of examples153-156, above.

Again, in some applications, a less cured portion may be desirable sothat it may be subsequently worked on by a subsequent process, such asto remove material and/or add a structural or other component tocomposite part 102, and a less cured portion may result from restrictionof the curing process.

Referring, e.g., to FIG. 1 and particularly to FIG. 32, (block 332) theportion of composite part 102 is restrictively cured to facilitatesubsequent processing of the portion of composite part 102. Thepreceding subject matter of this paragraph characterizes example 158 ofthe present disclosure, wherein example 158 also includes the subjectmatter according to example 157, above.

Subsequent processing on composite part 102 may be desirable, such as toremove material and/or add a structural or other component to compositepart 102.

Referring, e.g., to FIG. 1 and particularly to FIG. 32, (block 322)delivering the predetermined or actively determined amount of curingenergy 118 at least to portion 124 of segment 120 of continuous flexibleline 106 at the controlled rate comprises (block 334) selectivelyvarying at least one of a delivery rate, a delivery duration, or atemperature of curing energy 118 to impart varying physicalcharacteristics to composite part 102. The preceding subject matter ofthis paragraph characterizes example 159 of the present disclosure,wherein example 159 also includes the subject matter according to anyone of examples 153-158, above.

By imparting varying physical characteristics of composite part 102, acustomized composite part 102 may be manufactured with sub-parts havingdesirable properties that are different from other sub-parts.

Referring, e.g., to FIG. 1 and particularly to FIG. 32, (block 336) thevarying physical characteristics include at least one of strength,stiffness, flexibility, ductility, or hardness. The preceding subjectmatter of this paragraph characterizes example 160 of the presentdisclosure, wherein example 160 also includes the subject matteraccording to example 159, above.

Each of these physical characteristics may be selected for a particularpurpose. For example, in a composite part that when in use receives asignificant torque on a sub-part thereof compared to the remainder ofthe composite part, it may be desirable to have such sub-part less stiffand/or more flexible than other parts of the composite part.Additionally, it may be desirable to build more strength into a sub-partthan other parts of composite part 102 for various reasons depending ona specific application of composite part 102.

Referring, e.g., to FIG. 1 and particularly to FIG. 32, method 300further comprises, (block 338) simultaneously with delivering thepredetermined or actively determined amount of curing energy 118 atleast to portion 124 of segment 120 of continuous flexible line 106 atthe controlled rate, at least partially protecting at least portion 124of segment 120 of continuous flexible line 106 from oxidation aftersegment 120 exits delivery guide 112. The preceding subject matter ofthis paragraph characterizes example 161 of the present disclosure,wherein example 161 also includes the subject matter according to anyone of examples 153-160, above.

Protecting portion 124 from oxidation may facilitate the subsequentand/or simultaneous curing of portion 124.

Referring, e.g., to FIG. 1 and particularly to FIG. 32, (block 340) atleast portion 124 of segment 120 of continuous flexible line 106 is atleast partially protected from the oxidation with shielding gas 221. Thepreceding subject matter of this paragraph characterizes example 162 ofthe present disclosure, wherein example 162 also includes the subjectmatter according to example 161, above.

Again, protecting portion 124 from oxidation may facilitate thesubsequent and/or simultaneous curing of portion 124.

Referring, e.g., to FIGS. 1, 10-14, 21, and 23 and particularly to FIG.32, method 300 further comprises, (block 342) simultaneously withdepositing segment 120 of continuous flexible line 106 along print path122, compacting at least section 180 of segment 120 of continuousflexible line 106 after segment 120 of continuous flexible line 106 isdeposited along print path 122. The preceding subject matter of thisparagraph characterizes example 163 of the present disclosure, whereinexample 163 also includes the subject matter according to any one ofexamples 145-162, above.

Compaction of section 180 of continuous flexible line 106 duringperformance of method 300 facilitates adherence between adjacent layersof continuous flexible line 106 being deposited during performance ofmethod 300.

Referring, e.g., to FIGS. 1 and 11 and particularly to FIG. 32, (block342) compacting at least section 180 of segment 120 of continuousflexible line 106 after segment 120 of continuous flexible line 106 isdeposited along print path 122 comprises (block 344) imparting a desiredcross-sectional shape to segment 120 of continuous flexible line 106.The preceding subject matter of this paragraph characterizes example 164of the present disclosure, wherein example 164 also includes the subjectmatter according to example 163, above.

It may be desirable, in some applications, to impart a predeterminedcross-sectional shape to continuous flexible line 106 as it is beingdeposited.

Referring, e.g., to FIGS. 1 and 21 and particularly to FIG. 32, method300 further comprises, (block 346) simultaneously with depositingsegment 120 of continuous flexible line 106 along print path 122,roughening at least section 194 of segment 120 of continuous flexibleline 106 after segment 120 of continuous flexible line 106 is depositedalong print path 122. The preceding subject matter of this paragraphcharacterizes example 165 of the present disclosure, wherein example 165also includes the subject matter according to any one of examples145-164, above.

Roughening section 194 of continuous flexible line 106 increases thesurface area thereof and aids in adhesion of a subsequent layer ofcontinuous flexible line 106 deposited against it during performance ofmethod 300.

Referring, e.g., to FIGS. 1 and 21 and particularly to FIG. 32, method300 further comprises, (block 348) simultaneously with roughening atleast section 194 of segment 120 of continuous flexible line 106,collecting debris resulting from roughening at least section 194 ofsegment 120 of continuous flexible line 106. The preceding subjectmatter of this paragraph characterizes example 166 of the presentdisclosure, wherein example 166 also includes the subject matteraccording to example 165, above.

Collection of debris that results from roughening section 194 avoidsunwanted, loose particles of thermosetting-epoxy-resin component 110becoming trapped between adjacent deposited layers of continuousflexible line 106 that may otherwise result in unwanted properties ofcomposite part 102.

Referring, e.g., to FIGS. 1 and 21 and particularly to FIG. 32, method300 further comprises, (block 350) simultaneously with roughening atleast section 194 of segment 120 of continuous flexible line 106,dispersing debris resulting from roughening at least section 194 ofsegment 120 of continuous flexible line 106. The preceding subjectmatter of this paragraph characterizes example 167 of the presentdisclosure, wherein example 167 also includes the subject matteraccording to any one of examples 165 or 166, above.

Dispersal of debris that results from roughening section 194 avoidsunwanted, loose particles of thermosetting-epoxy-resin component 110becoming trapped between adjacent deposited layers of continuousflexible line 106 that may otherwise result in unwanted properties ofcomposite part 102.

Referring, e.g., to FIGS. 1, 15-18, 21, 30, and 31 and particularly toFIG. 32, method 300 further comprises (block 352) selectively cuttingcontinuous flexible line 106. The preceding subject matter of thisparagraph characterizes example 168 of the present disclosure, whereinexample 168 also includes the subject matter according to any one ofexamples 145-167, above.

Selective cutting of continuous flexible line 106 during performance ofmethod 300 permits for the stopping and starting of continuous flexibleline 106 in different locations on composite part 102.

Referring, e.g., to FIGS. 1, 15-18, 21, 30, and 31 and particularly toFIG. 32, (block 354) continuous flexible line 106 is selectively cutsimultaneously with depositing segment 120 of continuous flexible line106 along print path 122. The preceding subject matter of this paragraphcharacterizes example 169 of the present disclosure, wherein example 169also includes the subject matter according to example 168, above.

Simultaneous cutting and delivering of continuous flexible line 106provides for controlled deposition of continuous flexible line 106 alongprint path 122.

Referring, e.g., to FIG. 1 and particularly to FIG. 32, method 300further comprises, (block 356) simultaneously with depositing segment120 of continuous flexible line 106 along print path 122, detectingdefects in composite part 102. The preceding subject matter of thisparagraph characterizes example 170 of the present disclosure, whereinexample 170 also includes the subject matter according to any one ofexamples 145-169, above.

Detection of defects in segment 120 permits for selective scrapping ofcomposite parts 102 having defects prior to completion of compositeparts 102. Accordingly, less material may be wasted. Moreover, defectsthat otherwise would be hidden from view by various types of defectdetectors may be detected prior to a subsequent layer of continuousflexible line 106 obscuring, or hiding, the defect from view.

Referring, e.g., to FIG. 1 and particularly to FIG. 32, (block 304)depositing segment 120 of continuous flexible line 106 along print path122 comprises (block 358) depositing at least a portion of segment 120of continuous flexible line 106 over a sacrificial layer. The precedingsubject matter of this paragraph characterizes example 171 of thepresent disclosure, wherein example 171 also includes the subject matteraccording to any one of examples 145-170, above.

Use of a sacrificial layer may permit for deposition of an initial layerof continuous flexible line 106 in midair without requiring an outermold, surface 114, or other rigid structure for initial deposition ofthe initial layer. That is, the sacrificial layer may become an outermold for subsequent deposition of layers that are not sacrificial.Additionally or alternatively, the sacrificial layer may depositedwithin an internal volume of composite part 102, such as to facilitatethe formation of a void within composite part 102, with the sacrificiallayer remaining within the void or with the sacrificial layersubsequently being removed or otherwise disintegrated, for example, sothat it does impact the structural integrity of composite part 102.

Referring, e.g., to FIG. 1 and particularly to FIG. 32, method 300further comprises (block 360) removing the sacrificial layer to formcomposite part 102. The preceding subject matter of this paragraphcharacterizes example 172 of the present disclosure, wherein example 172also includes the subject matter according to example 171, above.

Removal of the sacrificial layer results in composite part 102 being ina desired state, which may be a completed state or may be a state thatis subsequently operated on by processes after completion of method 300.

Referring, e.g., to FIG. 1 and particularly to FIG. 32, method 300further comprises (block 362) depositing segment 120A of continuousflexible line 106A along print path 122. The preceding subject matter ofthis paragraph characterizes example 173 of the present disclosure,wherein example 173 also includes the subject matter according to anyone of examples 145-172, above.

In other words, different configurations of continuous flexible line 106may be used during performance of method 300.

For example, different properties of different continuous flexible lines106 may be selected for different sub-parts of composite part 102. As anexample, continuous flexible line 106 may comprise non-resin component108 that comprises carbon fiber for a significant portion of compositepart 102, but continuous flexible line 106 may comprise non-resincomponent 108 that comprises copper wiring for another portion to definean integral electrical path for connection to an electrical component.Additionally or alternatively, a different non-resin component 108 maybe selected for an outer surface of composite part 102 than non-resincomponent 108 selected for internal portions of composite part 102.Various other examples also are within the scope of example 173.

Referring, e.g., to FIG. 1 and particularly to FIG. 32, (block 364)continuous flexible line 106A differs from continuous flexible line 106in at least one of non-resin component 108 or thermosetting-epoxy-resincomponent 110. The preceding subject matter of this paragraphcharacterizes example 174 of the present disclosure, wherein example 174also includes the subject matter according to example 173, above.

Varying non-resin component 108 and/or thermosetting-epoxy-resincomponent 110 during performance of method 300 permits for customizedcomposite parts 102 to be manufactured with varying and desiredproperties throughout composite part 102.

Referring to FIG. 32, method 300 further comprises (block 366) curingcomposite part 102 in an autoclave or in an oven. The preceding subjectmatter of this paragraph characterizes example 175 of the presentdisclosure, wherein example 175 also includes the subject matteraccording to any one of examples 145-174, above.

In some applications, it may be desirable to not fully cure compositepart, in situ, that is, when continuous flexible line 106 is beingdeposited to form composite part 102. For example, as discussed, in someapplications, it may be desirable to not fully cure composite part, insitu, to permit for subsequent work on composite part 102. In suchapplications, following the subsequent work, a full cure may be achievedin an autoclave or oven.

Referring, e.g., to FIGS. 1-8 and 20-23 and particularly to FIG. 33,method 400 of additively manufacturing composite part 102 is disclosed.Method 400 comprises (block 402) depositing, via delivery guide 112,segment 120 of continuous flexible line 106 along print path 122.Continuous flexible line 106 comprises non-resin component 108 andthermosetting-epoxy-resin component 110 that is partially cured. Method400 also comprises (block 404) maintaining thermosetting-epoxy-resincomponent 110 of at least continuous flexible line 106 being advancedtoward print path 122 via delivery guide 112 below a thresholdtemperature prior to depositing segment 120 of continuous flexible line106 along print path 122. Method 400 further comprises (block 406)delivering a predetermined or actively determined amount of curingenergy 118 at least to portion 124 of segment 120 of continuous flexibleline 106 at a controlled rate while advancing continuous flexible line106 toward print path 122 and after segment 120 of continuous flexibleline 106 is deposited along print path 122 to at least partially cure atleast portion 124 of segment 120 of continuous flexible line 106. Thepreceding subject matter of this paragraph characterizes example 176 ofthe present disclosure.

Method 400 therefore may be performed to manufacture composite parts 102from at least a composite material that includes non-resin component 108and thermosetting-epoxy-resin component 110. Becausethermosetting-epoxy-resin component 110 is maintained below a thresholdtemperature prior to being deposited along print path 122, athermosetting epoxy resin may be selected for thermosetting-epoxy-resincomponent 110 to have desired properties.

As a result of delivering a predetermined or actively determined amountof curing energy 118 at a controlled rate, a desired level, or degree,of cure may be established with respect to portion 124 of segment 120 atany given time during manufacture of composite part 102. That is,composite part 102 may be cured at least partially in situ.Additionally, as discussed herein, in some examples, it may be desirableto cure one portion 124 greater than or less than another portion 124during manufacture of composite part 102.

Moreover, method 400 may be performed to manufacture composite parts 102with continuous flexible line 106 being oriented in desired and/orpredetermined orientations throughout composite part 102, such as todefine desired properties of composite part 102.

Referring, e.g., to FIGS. 1 and 4 and particularly to FIG. 33, (block406) delivering the predetermined or actively determined amount ofcuring energy 118 at least to portion 124 of segment 120 of continuousflexible line 106 at the controlled rate comprises (block 408) partiallycuring first layer 140 of segment 120 of continuous flexible line 106 asfirst layer 140 is being deposited and further curing first layer 140 assecond layer 142 is being deposited against first layer 140. Thepreceding subject matter of this paragraph characterizes example 177 ofthe present disclosure, wherein example 177 also includes the subjectmatter according to example 176, above.

By only partially curing first layer 140 as first layer 140 is beingdeposited, first layer 140 may remain tacky, or sticky, therebyfacilitating adhesion of second layer 142 against first layer 140 assecond layer 142 is deposited against first layer 140. Then, first layer140 is further cured as second layer 142 is being partially cured fordeposition of a subsequent layer against second layer 142, and so forth.

Referring, e.g., to FIGS. 1 and 4 and particularly to FIG. 33, (block406) delivering the predetermined or actively determined amount ofcuring energy 118 at least to portion 124 of segment 120 of continuousflexible line 106 at the controlled rate comprises (block 410) partiallycuring first layer 140 of segment 120 of continuous flexible line 106 asfirst layer 140 is being deposited and fully curing first layer 140 assecond layer 142 is being deposited against first layer 140. Thepreceding subject matter of this paragraph characterizes example 178 ofthe present disclosure, wherein example 178 also includes the subjectmatter according to any one of examples 176 or 177, above.

Again, by only partially curing first layer 140 as first layer 140 isbeing deposited, first layer 140 may remain tacky, or sticky, therebyfacilitating adhesion of second layer 142 against first layer 140 assecond layer 142 is deposited against first layer 140. However,according to this example 178, first layer 140 is fully cured as secondlayer 142 is being partially cured.

Referring, e.g., to FIG. 1 and particularly to FIG. 33, (block 406)delivering the predetermined or actively determined amount of curingenergy 118 at least to portion 124 of segment 120 of continuous flexibleline 106 at the controlled rate comprises (block 412) curing less thanan entirety of composite part 102. The preceding subject matter of thisparagraph characterizes example 179 of the present disclosure, whereinexample 179 also includes the subject matter according to any one ofexamples 176-178, above.

In some applications, a less cured portion may be desirable so that itmay be subsequently worked on by a subsequent process, such as to removematerial and/or add a structural or other component to composite part102.

Referring, e.g., to FIG. 1 and particularly to FIG. 33, method 400further comprises (block 414) restrictively curing at least a portion ofcomposite part 102. The preceding subject matter of this paragraphcharacterizes example 180 of the present disclosure, wherein example 180also includes the subject matter according to any one of examples176-179, above.

Again, in some applications, a less cured portion may be desirable sothat it may be subsequently worked on by a subsequent process, such asto remove material and/or add a structural or other component tocomposite part 102, and a less cured portion may result from restrictionof the curing process.

Referring, e.g., to FIG. 1 and particularly to FIG. 33, (block 416) theportion of composite part 102 is restrictively cured to facilitatesubsequent processing of the portion of composite part 102. Thepreceding subject matter of this paragraph characterizes example 181 ofthe present disclosure, wherein example 181 also includes the subjectmatter according to example 180, above.

Subsequent processing on composite part 102 may be desirable, such as toremove material and/or add a structural or other component to compositepart 102.

Referring, e.g., to FIG. 1 and particularly to FIG. 33, (block 406)delivering the predetermined or actively determined amount of curingenergy 118 at least to portion 124 of segment 120 of continuous flexibleline 106 at the controlled rate comprises (block 418) selectivelyvarying at least one of a delivery rate, a delivery duration, or atemperature of curing energy 118 to impart varying physicalcharacteristics to composite part 102. The preceding subject matter ofthis paragraph characterizes example 182 of the present disclosure,wherein example 182 also includes the subject matter according to anyone of examples 176-181, above.

By imparting varying physical characteristics of composite part 102, acustomized composite part 102 may be manufactured with sub-parts havingdesirable properties that are different from other sub-parts.

Referring, e.g., to FIG. 1 and particularly to FIG. 33, (block 420) thevarying physical characteristics include at least one of strength,stiffness, flexibility, ductility, or hardness. The preceding subjectmatter of this paragraph characterizes example 183 of the presentdisclosure, wherein example 183 also includes the subject matteraccording to example 182, above.

Each of these physical characteristics may be selected for a particularpurpose. For example, in a composite part that when in use receives asignificant torque on a sub-part thereof compared to the remainder ofthe composite part, it may be desirable to have such sub-part less stiffand/or more flexible than other parts of the composite part.Additionally, it may be desirable to build more strength into a sub-partthan other parts of composite part 102 for various reasons depending ona specific application of composite part 102.

Referring, e.g., to FIG. 1 and particularly to FIG. 33, method 400further comprises, (block 422) simultaneously with delivering thepredetermined or actively determined amount of curing energy 118 atleast to portion 124 of segment 120 of continuous flexible line 106 atthe controlled rate, at least partially protecting at least portion 124of segment 120 of continuous flexible line 106 from oxidation aftersegment 120 exits delivery guide 112. The preceding subject matter ofthis paragraph characterizes example 184 of the present disclosure,wherein example 184 also includes the subject matter according to anyone of examples 176-183, above.

Protecting portion 124 from oxidation may facilitate the subsequentand/or simultaneous curing of portion 124.

Referring, e.g., to FIG. 1 and particularly to FIG. 33, (block 424) atleast portion 124 of segment 120 of continuous flexible line 106 is atleast partially protected from the oxidation with shielding gas 221. Thepreceding subject matter of this paragraph characterizes example 185 ofthe present disclosure, wherein example 185 also includes the subjectmatter according to example 184, above.

Again, protecting portion 124 from oxidation may facilitate thesubsequent and/or simultaneous curing of portion 124.

Referring, e.g., to FIG. 1 and particularly to FIG. 33, method 400further comprises (block 426) pushing continuous flexible line 106through delivery guide 112. The preceding subject matter of thisparagraph characterizes example 186 of the present disclosure, whereinexample 186 also includes the subject matter according to any one ofexamples 176-185, above.

By pushing continuous flexible line 106 through delivery guide 112,delivery guide 112 may be positioned downstream of the source of motiveforce that pushes continuous flexible line 106, such as feed mechanism104 herein. As a result, such source of motive force does not interferewith deposition of continuous flexible line 106, and delivery guide 112may be more easily manipulated in complex three-dimensional patternsduring performance of method 300.

Referring to FIG. 33, (block 428) the threshold temperature is nogreater than 20° C., 15° C., 10° C., 5° C., 0° C., −50° C., −100° C.,−150° C., −200° C., −200-−100° C., −100-0° C., −50-5° C., 5-20° C.,5-15° C., or 5-10° C. The preceding subject matter of this paragraphcharacterizes example 187 of the present disclosure, wherein example 187also includes the subject matter according to any one of examples176-186, above.

The threshold temperature associated with method 400 may be selectedbased on a thermosetting epoxy resin being used forthermosetting-epoxy-resin component 110, and the examples set forth inexample 187 are illustrated and non-exclusive.

Referring to FIG. 33, (block 430) thermosetting-epoxy-resin component110 is configured to cure at a temperature between about 20° C. andabout 30° C. within a period greater than 5 minutes or to cure at atemperature greater than 150° C. within a period of less than 5 seconds.The preceding subject matter of this paragraph characterizes example 188of the present disclosure, wherein example 188 also includes the subjectmatter according to any one of examples 176-187, above.

Various thermosetting epoxy resins may be used forthermosetting-epoxy-resin component 110 and may be selected based on oneor more of desired properties prior to being fully cured, desiredproperties after being fully cured, desired curing properties, such asbased on length of time and/or temperatures required to fully cure, etc.The examples set forth in example 188 are illustrative andnon-exclusive, and other configurations of thermosetting-epoxy-resincomponent 110 may be used in connection with method 400.

Referring, e.g., to FIGS. 1-3 and particularly to FIG. 33, (block 432)continuous flexible line 106 comprises a prepreg composite material. Thepreceding subject matter of this paragraph characterizes example 189 ofthe present disclosure, wherein example 189 also includes the subjectmatter according to any one of examples 176-188, above.

Because continuous flexible line 106 comprises a prepreg compositematerial, the component parts of continuous flexible line 106, namelynon-resin component 108 and thermosetting-epoxy-resin component 110, maybe deposited along print path 122 as a continuous source material forcomposite part 102. Moreover, as composite part 102 is being formed, thenatural tackiness of the prepreg composite material may facilitateadhesion between layers being deposited by method 400.

Referring, e.g., to FIGS. 2 and 3 and particularly to FIG. 33, (block434) non-resin component 108 comprises one or more of a fiber, a carbonfiber, a glass fiber, a synthetic organic fiber, an aramid fiber, anatural fiber, a wood fiber, a boron fiber, a silicon-carbide fiber, anoptical fiber, a fiber bundle, a fiber tow, a fiber weave, a wire, ametal wire, a conductive wire, or a wire bundle. The preceding subjectmatter of this paragraph characterizes example 190 of the presentdisclosure, wherein example 190 also includes the subject matteraccording to any one of examples 176-189, above.

Inclusion of a fiber or fibers in continuous flexible line 106 permitsfor selecting desired properties of composite part 102. Moreover,selection of specific materials of fibers and/or selection of specificconfigurations of fibers (e.g., a bundle, a tow, and/or a weave) maypermit for precise selection of desired properties of composite part102. Example properties of composite parts 102 include strength,stiffness, flexibility, ductility, hardness, electrical conductivity,thermal conductivity, etc. Non-resin component 108 is not limited to theidentified examples, and other types of non-resin component 108 may beused.

FIG. 2 schematically represents continuous flexible line 106 with asingle fiber as non-resin component 108 within a matrix ofthermosetting-epoxy-resin component 110. FIG. 3 schematically representscontinuous flexible 106 with more than one fiber as non-resin component108 within a matrix of thermosetting-epoxy-resin component 110.

Referring, e.g., to FIGS. 1 and 4 and particularly to FIG. 33, (block402) depositing segment 120 of continuous flexible line 106 along printpath 122 comprises (block 436) layering continuous flexible line 106against itself or a previously deposited segment 120 to additivelymanufacture composite part 102. The preceding subject matter of thisparagraph characterizes example 191 of the present disclosure, whereinexample 191 also includes the subject matter according to any one ofexamples 176-190, above.

By layering continuous flexible line 106 against itself or a previouslydeposited segment 120, a three-dimensional composite part 102 may bemanufactured by performance of method 400.

Referring, e.g., to FIG. 1 and particularly to FIG. 33, (block 402)depositing segment 120 of continuous flexible line 106 along print path122 comprises (block 438) depositing continuous flexible line 106 in apredetermined pattern to selectively control one or more physicalcharacteristics of composite part 102. The preceding subject matter ofthis paragraph characterizes example 192 of the present disclosure,wherein example 192 also includes the subject matter according to anyone of examples 176-191, above.

By controlling one or more physical characteristics of composite part102, less overall material may be used and/or the size of a specificpart may be reduced when compared to a similar part manufactured by atraditional composite layup method.

For example, in contrast to composite parts constructed from multiplelayers of planar plies of composite material, composite part 102 may bemanufactured so that the orientation of continuous flexible line 106,and thus of non-resin component 108, results in desired properties. Asan example, if a part includes holes, continuous flexible line may bearranged generally in concentric circles or spiral around the holes,resulting in no or few interruptions to continuous flexible line 106 atthe boundary of the holes. As a result, the strength of the part may besignificantly greater around the hole than a similar part constructed bytraditional composite layup methods. In addition the part may be lesssubject to cracks and propagation thereof at the boundary of the holes.Moreover, because of the desired properties around the holes, theoverall thickness, volume, and/or mass of the part may be reduced whileachieving the desired properties, when compared to a similar partconstructed by traditional composite layup methods.

Referring, e.g., to FIG. 1 and particularly to FIG. 33, (block 440) thephysical characteristics include at least one of strength, stiffness,flexibility, ductility, or hardness. The preceding subject matter ofthis paragraph characterizes example 193 of the present disclosure,wherein example 193 also includes the subject matter according toexample 192, above.

Each of these physical characteristics may be selected for a particularpurpose. For example, in a composite part that when in use receives asignificant torque on a sub-part thereof compared to the remainder ofthe composite part, it may be desirable to have such sub-part less stiffand/or more flexible than other parts of the composite part.Additionally, it may be desirable to build more strength into a sub-partthan other parts of composite part 102 for various reasons depending ona specific application of composite part 102.

Referring, e.g., to FIGS. 1, 10-14, 21, and 23 and particularly to FIG.33, method 400 further comprises, (block 442) simultaneously withdepositing segment 120 of continuous flexible line 106 along print path122, compacting at least section 180 of segment 120 of continuousflexible line 106 after segment 120 of continuous flexible line 106 isdeposited along print path 122. The preceding subject matter of thisparagraph characterizes example 194 of the present disclosure, whereinexample 194 also includes the subject matter according to any one ofexamples 176-193, above.

Compaction of section 180 of continuous flexible line 106 duringperformance of method 300 facilitates adherence between adjacent layersof continuous flexible line 106 being deposited during performance ofmethod 400.

Referring, e.g., to FIGS. 1 and 11 and particularly to FIG. 33, (block442) compacting at least section 180 of segment 120 of continuousflexible line 106 after segment 120 of continuous flexible line 106 isdeposited along print path 122 comprises (block 444) imparting a desiredcross-sectional shape to segment 120 of continuous flexible line 106.The preceding subject matter of this paragraph characterizes example 195of the present disclosure, wherein example 195 also includes the subjectmatter according to example 194, above.

It may be desirable, in some applications, to impart a predeterminedcross-sectional shape to continuous flexible line 106 as it is beingdeposited.

Referring, e.g., to FIGS. 1 and 21 and particularly to FIG. 33, method400 further comprises, (block 446) simultaneously with depositingsegment 120 of continuous flexible line 106 along print path 122,roughening at least section 194 of segment 120 of continuous flexibleline 106 after segment 120 of continuous flexible line 106 is depositedalong print path 122. The preceding subject matter of this paragraphcharacterizes example 196 of the present disclosure, wherein example 196also includes the subject matter according to any one of examples176-195, above.

Roughening section 194 of continuous flexible line 106 increases thesurface area thereof and aids in adhesion of a subsequent layer ofcontinuous flexible line 106 deposited against it during performance ofmethod 300.

Referring, e.g., to FIGS. 1 and 21 and particularly to FIG. 33, method400 further comprises, (block 448) simultaneously with roughening atleast section 194 of segment 120 of continuous flexible line 106,collecting debris resulting from roughening at least section 194 ofsegment 120 of continuous flexible line 106. The preceding subjectmatter of this paragraph characterizes example 197 of the presentdisclosure, wherein example 197 also includes the subject matteraccording to example 196, above.

Collection of debris that results from roughening section 194 avoidsunwanted, loose particles of thermosetting-epoxy-resin component 110becoming trapped between adjacent deposited layers of continuousflexible line 106 that may otherwise result in unwanted properties ofcomposite part 102.

Referring, e.g., to FIGS. 1 and 21 and particularly to FIG. 33, method400 further comprises, (block 450) simultaneously with roughening atleast section 194 of segment 120 of continuous flexible line 106,dispersing debris resulting from roughening at least section 194 ofsegment 120 of continuous flexible line 106. The preceding subjectmatter of this paragraph characterizes example 198 of the presentdisclosure, wherein example 198 also includes the subject matteraccording to any one of examples 196 or 197, above.

Dispersal of debris that results from roughening section 194 avoidsunwanted, loose particles of thermosetting-epoxy-resin component 110becoming trapped between adjacent deposited layers of continuousflexible line 106 that may otherwise result in unwanted properties ofcomposite part 102.

Referring, e.g., to FIGS. 1, 15-18, 21, 30, and 31 and particularly toFIG. 33, method 400 further comprises (block 452) selectively cuttingcontinuous flexible line 106. The preceding subject matter of thisparagraph characterizes example 199 of the present disclosure, whereinexample 199 also includes the subject matter according to any one ofexamples 176-198, above.

Selective cutting of continuous flexible line 106 during performance ofmethod 300 permits for the stopping and starting of continuous flexibleline 106 in different locations on composite part 102.

Referring, e.g., to FIGS. 1, 15-18, 21, 30, and 31 and particularly toFIG. 33, (block 454) continuous flexible line 106 is selectively cutsimultaneously with depositing segment 120 of continuous flexible line106 along print path 122. The preceding subject matter of this paragraphcharacterizes example 200 of the present disclosure, wherein example 200also includes the subject matter according to example 199, above.

Simultaneous cutting and delivering of continuous flexible line 106provides for controlled deposition of continuous flexible line 106 alongprint path 122.

Referring, e.g., to FIG. 1 and particularly to FIG. 33, method 400further comprises, (block 456) simultaneously with depositing segment120 of continuous flexible line 106 along print path 122, detectingdefects in composite part 102. The preceding subject matter of thisparagraph characterizes example 201 of the present disclosure, whereinexample 201 also includes the subject matter according to any one ofexamples 176-200, above.

Detection of defects in segment 120 permits for selective scrapping ofcomposite parts 102 having defects prior to completion of compositeparts 102. Accordingly, less material may be wasted. Moreover, defectsthat otherwise would be hidden from view by various types of defectdetectors may be detected prior to a subsequent layer of continuousflexible line 106 obscuring, or hiding, the defect from view.

Referring, e.g., to FIG. 1 and particularly to FIG. 33, (block 402)depositing segment 120 of continuous flexible line 106 along print path122 comprises (block 458) depositing at least a portion of segment 120of continuous flexible line 106 over a sacrificial layer. The precedingsubject matter of this paragraph characterizes example 202 of thepresent disclosure, wherein example 202 also includes the subject matteraccording to any one of examples 176-201, above.

Use of a sacrificial layer may permit for deposition of an initial layerof continuous flexible line 106 in midair without requiring an outermold, surface 114, or other rigid structure for initial deposition ofthe initial layer. That is, the sacrificial layer may become an outermold for subsequent deposition of layers that are not sacrificial.Additionally or alternatively, the sacrificial layer may depositedwithin an internal volume of composite part 102, such as to facilitatethe formation of a void within composite part 102, with the sacrificiallayer remaining within the void or with the sacrificial layersubsequently being removed or otherwise disintegrated, for example, sothat it does impact the structural integrity of composite part 102.

Referring, e.g., to FIG. 1 and particularly to FIG. 33, method 400further comprises (block 460) removing the sacrificial layer to formcomposite part 102. The preceding subject matter of this paragraphcharacterizes example 203 of the present disclosure, wherein example 203also includes the subject matter according to example 202, above.

Removal of the sacrificial layer results in composite part 102 being ina desired state, which may be a completed state or may be a state thatis subsequently operated on by processes after completion of method 300.

Referring, e.g., to FIG. 1 and particularly to FIG. 33, method 400further comprises (block 462) depositing segment 120A of continuousflexible line 106A along print path 122. The preceding subject matter ofthis paragraph characterizes example 204 of the present disclosure,wherein example 204 also includes the subject matter according to anyone of examples 176-203, above.

In other words, different configurations of continuous flexible line 106may be used during performance of method 300.

For example, different properties of different continuous flexible lines106 may be selected for different sub-parts of composite part 102. As anexample, continuous flexible line 106 may comprise non-resin component108 that comprises carbon fiber for a significant portion of compositepart 102, but continuous flexible line 106 may comprise non-resincomponent 108 that comprises copper wiring for another portion to definean integral electrical path for connection to an electrical component.Additionally or alternatively, a different non-resin component 108 maybe selected for an outer surface of composite part 102 than non-resincomponent 108 selected for internal portions of composite part 102.Various other examples also are within the scope of example 204.

Referring, e.g., to FIG. 1 and particularly to FIG. 33, (block 464)continuous flexible line 106A differs from continuous flexible line 106in at least one of non-resin component 108 or thermosetting-epoxy-resincomponent 110. The preceding subject matter of this paragraphcharacterizes example 205 of the present disclosure, wherein example 205also includes the subject matter according to example 204, above.

Varying non-resin component 108 and/or thermosetting-epoxy-resincomponent 110 during performance of method 300 permits for customizedcomposite parts 102 to be manufactured with varying and desiredproperties throughout composite part 102.

Referring to FIG. 33, method 400 further comprises (block 466) curingcomposite part 102 in an autoclave or in an oven. The preceding subjectmatter of this paragraph characterizes example 206 of the presentdisclosure, wherein example 206 also includes the subject matteraccording to any one of examples 176-205, above.

In some applications, it may be desirable to not fully cure compositepart, in situ, that is, when continuous flexible line 106 is beingdeposited to form composite part 102. For example, as discussed, in someapplications, it may be desirable to not fully cure composite part, insitu, to permit for subsequent work on composite part 102. In suchapplications, following the subsequent work, a full cure may be achievedin an autoclave or oven.

Examples of the present disclosure may be described in the context ofaircraft manufacturing and service method 1100 as shown in FIG. 34 andaircraft 1102 as shown in FIG. 35. During pre-production, illustrativemethod 1100 may include specification and design (block 1104) ofaircraft 1102 and material procurement (block 1106). During production,component and subassembly manufacturing (block 1108) and systemintegration block 1110 of aircraft 1102 may take place. Thereafter,aircraft 1102 may go through certification and delivery (block 1112) tobe placed in service (block 1114). While in service, aircraft 1102 maybe scheduled for routine maintenance and service (block 1116). Routinemaintenance and service may include modification, reconfiguration,refurbishment, etc. of one or more systems of aircraft 1102.

Each of the processes of illustrative method 1100 may be performed orcarried out by a system integrator, a third party, and/or an operatore.g., a customer. For the purposes of this description, a systemintegrator may include, without limitation, any number of aircraftmanufacturers and major-system subcontractors; a third party mayinclude, without limitation, any number of vendors, subcontractors, andsuppliers; and an operator may be an airline, leasing company, militaryentity, service organization, and so on.

As shown in FIG. 34, aircraft 1102 produced by illustrative method 1100may include airframe 1118 with a plurality of high-level systems 1120and interior 1122. Examples of high-level systems 1120 include one ormore of propulsion system 1124, electrical system 1126, hydraulic system1128, and environmental system 1130. Any number of other systems may beincluded. Although an aerospace example is shown, the principlesdisclosed herein may be applied to other industries, such as theautomotive industry. Accordingly, in addition to aircraft 1102, theprinciples disclosed herein may apply to other vehicles, e.g., landvehicles, marine vehicles, space vehicles, etc.

Apparatus(es) and method(s) shown or described herein may be employedduring any one or more of the stages of the manufacturing and servicemethod 1100. For example, components or subassemblies corresponding tocomponent and subassembly manufacturing (block 1108) may be fabricatedor manufactured in a manner similar to components or subassembliesproduced while aircraft 1102 is in service (block 1114). Also, one ormore examples of the apparatus(es), method(s), or combination thereofmay be utilized during production stages 1108 and 1110, for example, bysubstantially expediting assembly of or reducing the cost of aircraft1102. Similarly, one or more examples of the apparatus or methodrealizations, or a combination thereof, may be utilized, for example andwithout limitation, while aircraft 1102 is in service (block 1114)and/or during maintenance and service (block 1116).

Different examples of the apparatus(es) and method(s) disclosed hereininclude a variety of components, features, and functionalities. Itshould be understood that the various examples of the apparatus(es) andmethod(s) disclosed herein may include any of the components, features,and functionalities of any of the other examples of the apparatus(es)and method(s) disclosed herein in any combination, and all of suchpossibilities are intended to be within the scope of the presentdisclosure.

Many modifications of examples set forth herein will come to mind to oneskilled in the art to which the present disclosure pertains having thebenefit of the teachings presented in the foregoing descriptions and theassociated drawings.

Therefore, it is to be understood that the present disclosure is not tobe limited to the specific examples illustrated and that modificationsand other examples are intended to be included within the scope of theappended claims. Moreover, although the foregoing description and theassociated drawings describe examples of the present disclosure in thecontext of certain illustrative combinations of elements and/orfunctions, it should be appreciated that different combinations ofelements and/or functions may be provided by alternative implementationswithout departing from the scope of the appended claims. Accordingly,parenthetical reference numerals in the appended claims are presentedfor illustrative purposes only and are not intended to limit the scopeof the claimed subject matter to the specific examples provided in thepresent disclosure.

1. A system (100) for additively manufacturing a composite part (102),the system (100) comprising: a delivery guide (112), movable relative toa surface (114), wherein: the delivery guide (112) is configured todeposit at least a segment (120) of a continuous flexible line (106)along a print path (122); the print path (122) is stationary relative tothe surface (114); and the continuous flexible line (106) comprises anon-resin component (108) and a thermosetting-epoxy-resin component(110) that is partially cured; a feed mechanism (104), configured topush the continuous flexible line (106) through the delivery guide(112); and a cooling system (234), configured to maintain thethermosetting-epoxy-resin component (110) of the continuous flexibleline (106) below a threshold temperature prior to depositing the segment(120) of the continuous flexible (106) along the print path (122) viathe delivery guide (112).
 2. (canceled)
 3. The system (100) according toclaim 1, wherein the continuous flexible line (106) comprises a prepregcomposite material, and wherein the non-resin component (108) of thecontinuous flexible line (106) comprises one or more of a fiber, acarbon fiber, a glass fiber, a synthetic organic fiber, an aramid fiber,a natural fiber, a wood fiber, a boron fiber, a silicon-carbide fiber,an optical fiber, a fiber bundle, a fiber tow, a fiber weave, a wire, ametal wire, a conductive wire, or a wire bundle. 4-5. (canceled)
 6. Thesystem (100) according to claim 1, further comprising an origin (126) ofthe continuous flexible line (106), wherein: the cooling system (234)comprises an insulated store (244), and the origin (126) is positionedwithin the insulated store (244).
 7. (canceled)
 8. The system (100)according to claim 6, wherein: the cooling system (234) comprises a pump(238) and a coolant line (240), communicatively coupled with the pump(238) and thermally coupled with the insulated store (244), and the pump(238) is configured to circulate a coolant (246) through the coolantline (240) to cool the insulated store (244).
 9. (canceled)
 10. Thesystem (100) according to claim 1, wherein: the cooling system (234)comprises an insulated sleeve (242), and the feed mechanism (104) isconfigured to pull the continuous flexible line (106) through theinsulated sleeve (242).
 11. The system (100) according to claim 1,further comprising a source (116) of curing energy (118), wherein thesource (116) is configured to deliver the curing energy (118) at leastto a portion (124) of the segment (120) of the continuous flexible line(106) after the segment (120) of the continuous flexible line (106)exits the delivery guide (112).
 12. The system (100) according to claim11, wherein the source (116) of the curing energy (118) is configured todeliver the curing energy (118) at least to the portion (124) of thesegment (120) of the continuous flexible line (106) as the feedmechanism (104) pushes the continuous flexible line (106) through thedelivery guide (112) toward the print path (122) and after the segment(120) of the continuous flexible line (106) is deposited along the printpath (122).
 13. The system (100) according to claim 11, wherein thesource (116) of the curing energy (118) is configured to deliver apredetermined or actively determined amount of the curing energy (118)at a controlled rate at least to the portion (124) of the segment (120)of the continuous flexible line (106). 14-18. (canceled)
 19. The system(100) according to claim 11, wherein: the source (116) of the curingenergy (118) comprises a heat source (136); the heat source (136)comprises a convective heat source (250); and the curing energy (118)comprises a hot gas stream.
 20. The system (100) according to claim 11,wherein the source (116) of the curing energy (118) comprises a heatsource (136), and wherein the heat source (136) comprises a radiativeheat source (252).
 21. The system (100) according to claim 11, furthercomprising a chamber (258), wherein: the source (116) of the curingenergy (118) comprises a heat source (136); the delivery guide (112) andthe feed mechanism (104) are positioned within the chamber (258); thedelivery guide (112) is configured to deposit the segment (120) of thecontinuous flexible line (106) along the print path (122) within thechamber (258); and wherein the heat source (136) is configured to heatthe chamber (258). 22-23. (canceled)
 24. The system (100) according toclaim 11, further comprising a compactor (138), operatively coupled tothe delivery guide (112), wherein: the source (116) of the curing energy(118) comprises a heat source (136); the heat source (136) comprises aconductive heat source (254); the compactor (138) is configured toimpart a compaction force at least to a section (180) of the segment(120) of the continuous flexible line (106) after the segment (120) ofthe continuous flexible line (106) exits the delivery guide (112); andthe compactor (138) comprises the conductive heat source (254). 25-32.(canceled)
 33. The system (100) according to claim 24, wherein thecompactor (138) is configured to trail the delivery guide (112) when thedelivery guide (112) moves relative to the surface (114). 34-37.(canceled)
 38. The system (100) according to claim 11, furthercomprising a surface roughener (144) operatively coupled to the deliveryguide (112), wherein: the source (116) of the curing energy (118)comprises a heat source (136); the heat source (136) comprises aconductive heat source (254); the surface roughener (144) is configuredto abrade at least a section (194) of the segment (120) of thecontinuous flexible line (106) after the segment (120) of the continuousflexible line (106) exits the delivery guide (112); and the surfaceroughener (144) comprises the conductive heat source (254). 39-43.(canceled)
 44. The system (100) according to claim 38, wherein thesurface roughener (144) is configured to trail the delivery guide (112)when the delivery guide (112) moves relative to the surface (114).45-47. (canceled)
 48. The system (100) according to claim 38, furthercomprising a compactor (138), wherein the surface roughener (144) ispositioned to abrade at least the section (194) of the segment (120) ofthe continuous flexible line (106) following compaction of at least thesection (194) by the compactor (138). 49-66. (canceled)
 67. The system(100) according to claim 11, wherein the source (116) of the curingenergy (118) is configured to partially cure a first layer (140) of thesegment (120) of the continuous flexible line (106) as at least aportion of the first layer (140) is being deposited by the deliveryguide (112) against the surface (114) and to further cure the firstlayer (140) and to partially cure a second layer (142) as the secondlayer (142) is being deposited by the delivery guide (112) against thefirst layer (140). 68-104. (canceled)
 105. The system (100) according toclaim 1, wherein: the delivery guide (112) comprises a line passage(154) through which the continuous flexible line (106) is delivered tothe print path (122); the line passage (154) of the delivery guide (112)has an inlet (170); the feed mechanism (104) is configured to push thecontinuous flexible line (106) through the line passage (154); the feedmechanism (104) comprises a support frame (156) and opposing rollers(157) having respective rotational axes (159); the opposing rollers(157) are rotatably coupled to the support frame (156); the opposingrollers (157) are configured to engage opposite sides of the continuousflexible line (106); and the opposing rollers (157) are configured toselectively rotate to push the continuous flexible line (106) throughthe line passage (154). 106-120. (canceled)
 121. The system (100)according to claim 1, wherein the delivery guide (112) comprises a linepassage (154) through which the continuous flexible line (106) isdelivered to the print path (122) and the line passage (154) comprisesan outlet (206), the system (100) further comprising a cutter (208),configured to selectively cut the continuous flexible line (106)adjacent to the outlet (206). 122-137. (canceled)
 138. The system (100)according to claim 1, further comprising a defect detector (224),configured to detect defects in the segment (120) of the continuousflexible line (106) after the segment (120) of the continuous flexibleline (106) exits the delivery guide (112). 139-206. (canceled)